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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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SEBU8406-04 May 2011

Operation and Maintenance Manual
793F and 793F XQ Off-Highway Truck
SND1-Up (Machine) SSP1-Up (Machine)

SAFETY.CAT.COM

SEBU8406-04

137 Maintenance Section Maintenance Interval Schedule

i04322549

Maintenance Interval Schedule
SMCS Code: 1000; 7000 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging are included. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals. Note: The aftertreatment system can be expected to function properly for the useful life of the engine (emissions durability period), as defined by regulation. All prescribed maintenance requirements must be followed. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced hydraulic oils are used, the hydraulic oil change interval is extended to 3000 hours. S·O·S services may extend the oil change even longer. Consult your Cat dealer for details.

Fuel System Primary Filter (Water Separator) Drain ................................................................. 185 Fuses, Circuit Breakers and Relays Replace/Reset .................................................. 188 High Intensity Discharge Lamp (HID) - Replace .. 194 Hoist Screens - Clean ......................................... 195 Oil Filter - Inspect ................................................ 209 Radiator, Aftercooler and Air Conditioner Condenser - Clean .............................................................. 210 Rim - Inspect ....................................................... 215 Torque Converter Sump Screen - Clean ............. 226 Traction Control System (TCS) - Test ................. 229 Window Washer Bottle - Fill ................................ 231 Window Wiper - Inspect/Replace ........................ 232 Windows - Clean ................................................. 232

Every 10 Service Hours or Daily
Air Tank Moisture and Sediment - Drain ............. Backup Alarm - Test ............................................ Braking System - Test ......................................... Cooling System Coolant Level - Check .............. Differential and Final Drive Oil Level - Check ..... Engine Oil Level - Check .................................... Front Wheel Oil Level - Check ............................ Hydraulic Tank Oil Level - Check ........................ Hydraulic Tank Oil Level - Check ........................ Indicators and Gauges - Test .............................. Seat Belt - Inspect .............................................. Torque Converter Sump Oil Level - Check ......... 142 144 148 158 164 173 182 206 207 207 216 226

Initial 50 Service Hours
Hydraulic Oil Filter - Replace .............................. Hydraulic Oil Filter - Replace .............................. Hydraulic Oil Filter - Replace .............................. Hydraulic Oil Filter - Replace .............................. Rear Axle Oil Filter - Replace ............................. Torque Converter Oil Filter - Replace ................. Transmission Oil Filter - Replace ........................ 197 198 199 201 212 224 231

Initial 250 Service Hours
Engine Valve Lash - Check/Adjust ...................... 177

When Required
Air Conditioner Filter - Clean .............................. Air Tank - Inspect ................................................ Automatic Lubrication Reservoir - Fill ................. Battery - Recycle ................................................ Battery or Battery Cable - Inspect/Replace ........ Brake Oil Cooler Screen - Clean ........................ Cab Air Filter - Clean/Replace ............................ Display and Camera - Clean ............................... Engine Air Filter Primary Element - Clean/ Replace ............................................................. Engine Air Filter Secondary Element - Replace .. Engine Air Precleaner - Clean ............................ Ether Starting Aid Cylinder - Replace ................. Film (Product Identification) - Clean ................... Fuel System - Fill ................................................ Fuel System - Prime ........................................... 140 142 143 144 144 147 153 165 168 169 170 178 179 183 184

Every 250 Service Hours or Monthly
Magnetic Plug (Wheels) - Check ........................ 208 Tire Inflation - Check ........................................... 223

Every 500 Service Hours
Cooling System Coolant Sample (Level 1) Obtain ............................................................... 159 Differential and Final Drive Oil Sample - Obtain .. 164 Engine Oil Sample - Obtain ................................ 174 Front Wheel Oil Sample - Obtain ........................ 182 Hydraulic System Oil Sample - Obtain ............... 202 Hydraulic System Oil Sample - Obtain ............... 202 Torque Converter and Transmission Oil Sample Obtain ............................................................... 228

..........Clean ............ 217 Every 1000 Service Hours or 6 Months Air Dryer Desiccant ..........Change ................. 225 Transmission Magnetic Screen ....................... 141 Frame and Body .Inspect/Replace ...Replace ......Check ........ 222 Every 15 000 Service Hours Rim ........... 217 Suspension Cylinder .......Replace ... 154 Differential and Final Drive Oil .....Replace ..................................................................................... 172 ...Replace . 222 Torque Converter Oil Filter .......................Check/Adjust ....Clean/Inspect . 164 Electric Drive Pump (Powered Stairway) Oil Level Check ............Replace .......................Clean/Replace ......... 214 Every 3000 Service Hours or 2 Years Cooling System Coolant Extender (ELC) ...... 167 Engine Crankcase Breather ....................... 166 Steering Ball Stud ......... 154 Every 12 000 Service Hours or 6 Years Drive Shaft Spider and Bearing ............................... 152 Breather (Torque Converter and Transmission) Replace . 180 Hydraulic Oil Filter ........... 221 Steering Linkage ..... 187 Hoses and Clamps ....... 196 Platform (Powered Stairway) .......Check ............ 159 Electric Drive Pump (Powered Stairway) Oil Change ............. 211 Rollover Protective Structure (ROPS) ................................Inspect/Lubricate . 140 Air Dryer ..........Replace ................. 172 Engine Oil and Filter ............ 199 Hydraulic Oil Filter ............................................. 227 Transmission Oil Filter .............. Differential Thrust Pin Clearance .....Replace .................... 156 Cooling System Pressure Cap .......Clean/Inspect .................................... 186 Fuel Tank Water and Sediment ........................... 153 Cable (Truck Body Retaining) ....... 181 Front Wheel Oil ........ 223 Torque Converter Outlet Screen ....Check ..................Change .Clean ............ Damper (Crankshaft) .....................................................Replace ..............Inspect .................. 231 Every 4000 Service Hours Engine Valve Lash ............Replace .... 145 Breather (Fuel Tank) ....................... 160 Cooling System Relief Valve .............Inspect ............. Hydraulic Tank Oil .................... 151 Breather (Steering Tank) .......................................Check ..........Inspect ..... 208 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Seat Belt ............ 150 Every 1 704 700 L (450 000 US gal) of Fuel or 9000 Service Hours Engine Components ........... Lubrication Pump Oil ...............................Inspect ...... 201 Rear Axle Lubrication Magnetic Screen ... 216 Seat Suspension ......Change ..... Panels) Inspect/Replace ........ 180 Frame and Body Support Pads ..Replace ..Clean ......................Replace ..Inspect .......... 152 Cab Air Filter .......................Check ......................Rebuild/Install Reman .......Replace ...................Inspect .....Inspect ..................... 150 161 162 203 205 207 Every Year Cooling System Coolant Sample (Level 2) Obtain ..... 217 Service Brakes ..............................Change ........................ 140 Belts .......Replace .......................................Clean .......Add ................. 185 Fuel System Secondary Filter .....Clean ....................Replace .................. Aftercooler and Air Conditioner Condenser ........ 177 Every 6000 Service Hours or 4 Years Cooling System Coolant (ELC) .... 212 Secondary Steering ........... 198 Hydraulic Oil Filter .Replace ............ 182 Fuel System Primary Filter (Water Separator) Replace ....... 162 Engine Water Pump ..Clean ........ 166 Every 1000 Service Hours or 1 Year Breather (Differential and Final Drive) ........... 214 Every 24 000 Service Hours Drive Shaft Slip Joint .............................Clean/Replace .......... 174 Frame ...............................Replace ... 179 Front Wheel Oil ..........Replace ............Change ............ 210 Rear Axle Oil Filter ....................Inspect ............................. 230 Every 2000 Service Hours or 1 Year Breather (Front Axle) ................Change ...................................Replace .................. 197 Hydraulic Oil Filter ......................Change .............................Inspect ... 161 Differential and Final Drive Oil ...Inspect/Replace ........ 166 Sound Suppression (Covers........................... 224 Torque Converter and Transmission Oil Change .........Inspect ............................................Lubricate ..Replace ................................ 219 Steering Ball Stud ............Inspect ..138 Maintenance Section Maintenance Interval Schedule SEBU8406-04 Every 500 Service Hours or 3 Months Air Conditioner Filter ... 151 Breather (Hoist and Brake Tank) .................. Hydraulic Tank Oil ................ 177 Radiator.................Drain ...... 210 Every 750 Service Hours or Monthly Lubrication Pump Oil Level ............................. 220 Every 2 Years Receiver Dryer (Refrigerant) ..............Replace .........................

Clean/Inspect.............. Rebuild/Install Reman................. 171 ... Install New .SEBU8406-04 139 Maintenance Section Maintenance Interval Schedule Every 3 407 000 L (900 000 US gal) of Fuel or 18 000 Service Hours Engine Components ............

Use caution when working between the wheels and the frame. 5. Refer to Operation and Maintenance Manual. Inspect the air filter element for damage to the seal.Clean SEBU8406-04 i03702882 Air Conditioner Filter . The steering system is hydraulically controlled and wheels can crush personnel during movement. clean the radial seal air filter for the air conditioner. Prepare the machine for maintenance.Drain” for the proper procedure. Prepare the machine for maintenance. Visually inspect the air filter element before cleaning. The air lines to and from the air dryer must be at atmospheric pressure. Replace a damaged air filter element with a new air filter element. Refer to Operation and Maintenance Manual. 4. Air pressure must not exceed 207 kPa (30 psi). “Air Tank Moisture and Sediment . Refer to Operation and Maintenance Manual. Use low pressure compressed air in order to remove the dust from the dirty air filter element. 2. “Prepare the Machine for Maintenance”. personal injury could result. i03446760 Air Dryer . . 1. 1.Clean SMCS Code: 7320-070-FI If a reduction in air circulation is noticed. Direct the air flow up the pleats and down the pleats from the inside of the filter element.Check (If Equipped with Air Start) SMCS Code: 4285-535 S/N: SSP1-Up Personal injury or death can occur if personnel are trapped between the wheel and the frame. and the outer cover. Release the air pressure from the air system completely before performing maintenance. If the air lines are not at atmospheric pressure. ensure that all personnel are clear of the machine before any movement. Take extreme care in order to avoid damage to the pleats. “Prepare the Machine for Maintenance”. If the wheels must be turned. Illustration 141 g01993019 2. the pleats. Open the access door and remove air filter element (1). Install the clean air filter element and close the access door. 3.140 Maintenance Section Air Conditioner Filter . Drain the air tank. The air filter element for the air conditioner is located behind the access door on the left rear of the cab.

The steering system is hydraulically controlled and wheels can crush personnel during movement. “Prepare the Machine for Maintenance”. Note: For more information on the operation of the air dryer. “Air Dryer”. Release the air pressure from the air system completely before performing maintenance. Refer to Operation and Maintenance Manual. refer to Systems Operation/Testing and Adjusting.Replace (If Equipped with Air Start) SMCS Code: 4285-510-DSS S/N: SSP1-Up Personal injury or death can occur if personnel are trapped between the wheel and the frame. 3.SEBU8406-04 141 Maintenance Section Air Dryer Desiccant . If the wheels must be turned. Illustration 142 g01793693 Air dryer (1) is located on the outside frame rail in front of the right front suspension cylinder. Note: Small amounts of moisture may be in the system due to condensation in the system. “793F Off-Highway Truck Air System and Brakes”. ensure that all personnel are clear of the machine before any movement. If there is moisture in the air tank. Prepare the machine for maintenance. 1. replace the desiccant cartridge. Air lines to and from the air dryer must be at atmospheric pressure. Use caution when working between the wheels and the frame. Consult your Caterpillar dealer for information about replacing the desiccant cartridge. . KENR8572.Replace i03447800 Air Dryer Desiccant .

“Prepare the Machine for Maintenance”. Replace the air dryer desiccant cartridge if water cannot be absorbed. KENR8579.Assemble” or consult your Caterpillar dealer. refer to Disassembly and Assembly.Inspect SEBU8406-04 i03447866 Air Tank Moisture and Sediment . 2.Drain (If Equipped with Air Start) SMCS Code: 4272-543-MAS S/N: SSP1-Up Personal injury or death can occur if personnel are trapped between the wheel and the frame. 7428-040 S/N: SSP1-Up When laws in the machine's operating location require the inspection of air tanks. “793F Off-Highway Truck Machine Systems”. “Air Dryer .797”. “Air Dryer .142 Maintenance Section Air Tank . REHS2398. Use caution when working between the wheels and the frame. ensure that all personnel are clear of the machine before any movement. If the wheels must be turned. 5505-040.Inspect SMCS Code: 4272-040. Illustration 143 g01793693 Air dryer (1) is located on the outside frame rail in front of the right front suspension cylinder. refer to Special Instruction. In order to replace the desiccant cartridge. “Air Tank Inspection for the Off-Highway Truck 769 . i02444297 Air Tank . The steering system is hydraulically controlled and wheels can crush personnel during movement. Refer to Operation and Maintenance Manual.Disassemble” and. 1. Prepare the machine for maintenance. .

4. “Prepare the Machine for Maintenance”. Check for moisture and sediment in the air tank. Also.Fill Illustration 145 g02042673 Machines that are equipped with the electric start use an electric motor on the automatic lubrication pump. Illustration 144 g01794486 Air tank drain valve (1) is located on the outside frame rail in front of the right front suspension cylinder. . 2. Open drain valve (1) for the air tank.SEBU8406-04 143 Maintenance Section Automatic Lubrication Reservoir . 3. Fill the autolube reservoir through fast fill port (2). Illustration 146 i03770671 g02042676 Automatic Lubrication Reservoir . 3.Fill SMCS Code: 7540-544-TNK 1. Drain the moisture and sediment from the air tank into a suitable container. Prepare the machine for maintenance. Close the drain valve for the air tank. grease on the top side of the follower assembly may cause damage to the autolube system. Remove plug (1) for the vent port if the reservoir is not equipped with a permanent vent. Machines that are equipped with the air start use an air motor on the automatic lubrication pump. 2. Note: If the reservoir is not properly vented. Refer to Operation and Maintenance Manual. pressure will cause the wiper seal on the follower assembly inside the reservoir to fail when the reservoir is filled. Grease on the top side of the follower assembly may prevent the autolube system from functioning properly.

Move the transmission control to the P position and release the service brake. They could cause vapors to explode. contact your Caterpillar dealer. Improper jump start procedures can cause an explosion resulting in personal injury. 6. Do not smoke when checking battery electrolyte levels. Open a door or a window. 3. . The backup alarm should sound immediately. or if the backup alarm did not function properly. 2. 1. If the backup alarm did not function. 5. install a fitting in place of the remote line. they will operate when the energy source is connected. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Prevent sparks near the batteries. The backup alarm should continue to sound until the transmission control is moved out of the R position. Jump start only with an energy source with the same voltage as the stalled machine. Never discard a battery. 5. Failure to properly service the batteries may cause peronal injury. Turn the fan speed switch to the OFF position and turn off the entertainment radio (if equipped). There are five banks of injectors on the machine. The automatic lubrication reservoir provides lubrication for many components. Install the plug in the vent port if the reservoir is not equipped with a permanent vent. 8. Lubricate the item at the fittings until the remote line can be replaced. The backup alarm is located at the rear of the machine. 7. 1402-040. Turn the engine start switch to the ON position. Otherwise. 4. Move the transmission control to the R position and listen for the backup alarm. Turn off all lights and accessories on the stalled machine. Note: Level indicator (3) can also be used in order to determine when the reservoir is full. 1401-510. Apply the service brakes. Make sure that the area behind the machine is clear of personnel and clear of obstacles. i03652288 i00993589 Battery .Recycle SMCS Code: 1401-561 Always recycle a battery. Do not allow the jump start cable ends to contact each other or the machine. 1402-510 Backup Alarm . Park the machine on a level surface and stop the engine. Note: Do not start the engine.144 Maintenance Section Backup Alarm . Always connect the battery positive (+) to battery positive (+) and the battery negative (−) to battery negative (−). Fill the reservoir until grease appears at the outlet for the vent port. Always wear eye protection when starting a machine with jump start cables. Note: The bulk capacity of the grease reservoir is 27 kg (60 lb).Test SEBU8406-04 4.Test SMCS Code: 7406-081 The backup alarm alerts the personnel behind the machine that the machine is backing up. Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility • Recycling facility i04334142 Battery or Battery Cable Inspect/Replace SMCS Code: 1401-040. If any of the remote lines become damaged.

4. 10. Prepare the machine for maintenance. Note: Do not allow the disconnected battery cable to contact the battery disconnect switch. 2. 5. “Prepare the Machine for Maintenance”. 1397-510 Note: In order to view the belts. Install the battery access covers. Replace the battery or make all necessary repairs to the battery. This machine requires Maintenance Free batteries or Low Maintenance High Output batteries. Turn the battery disconnect switch to the ON position. or other portable access system) that is suitable and compliant to local regulations. Connect the negative end “−” of the battery cable to the battery. Connect the negative end “−” of the battery cable to the frame near the battery disconnect switch. stair assembly. . Disconnect the negative end “−” of the battery cable from the battery. Prepare the machine for maintenance. Connect the positive end “+” of the battery cable to the battery. Turn all of the switches to the OFF position. Refer to Operation and Maintenance Manual.Inspect/Replace 6.SEBU8406-04 145 Maintenance Section Belts . 1. Lock out the battery disconnect switch. “Prepare the Machine for Maintenance”. Remove the battery access covers. it may be necessary to use a portable access system (ladder.Inspect/Replace SMCS Code: 1397-040. i04030841 Belts . Turn the engine start switch to the OFF position. Remove the lockout for the battery disconnect switch. 8. Refer to Operation and Maintenance Manual. 11. man lift. always use the same type of battery. Note: When the batteries are replaced. 3. Illustration 148 g02489677 Batteries for serial number prefix SND are located on the right platform. 13. Inspection Refrigerant Compressor Belt This machine is equipped with a serpentine belt that drives the refrigerant compressor. 12. Disconnect the positive end “+” of the battery cable from the battery. 9. Illustration 147 g01794777 Batteries for serial number prefix SSP are located on the front bumper. Disconnect the negative end “−” of the battery cable from the frame near the battery disconnect switch. Turn the battery disconnect switch to the OFF position. 7.

frayed areas. Inspect the refrigerant compressor belt for the following conditions: cracks. . Do not remove the belt guard for inspection. g02220973 Rear view of refrigerant compressor belt arrangement for reference. If necessary. wear. If necessary.146 Maintenance Section Belts . Do not remove the belt guard for inspection. Illustration 150 g02220896 Illustration 152 Front view of alternator belt arrangement for reference. “793F Off-Highway Truck Engine Supplement” for information on replacing the refrigerant compressor belt and the alternator belt. KENR8578. Alternator Belt This machine is equipped with a serpentine belt that drives the alternator. Inspect the alternator belt through the areas that are not obstructed by the belt guard. frayed areas. wear. replace the belt. and missing pieces. Replacement Refer to Disassembly and Assembly. replace the belt.Inspect/Replace SEBU8406-04 Illustration 149 g02162032 Illustration 151 g02162033 Inspect the refrigerant compressor belt through the areas that are not obstructed by the belt guard. stretch. stretch. Inspect the alternator belt for the following conditions: cracks. and missing pieces.

Refer to Special Publication. Refer to Operation and Maintenance Manual. Install the rear tow point pins through the ends of the retaining cables. maintenance. 1. testing. Failure to properly secure the body (bed) may result in personal injury or death. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. NENG2500. Clean the brake oil cooler screen(s) whenever there is a failure in the brake circuit. 4295-070 When it is necessary to work under the machine with the body (bed) raised.Clean i03591340 Brake Oil Cooler Screen Clean SMCS Code: 4257-070. Do not allow hot oil or hot components to contact the skin. adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.SEBU8406-04 147 Maintenance Section Brake Oil Cooler Screen . Dispose of all fluids according to local regulations and mandates. Hot oil and hot components can cause personal injury. Illustration 153 g01917255 (1) Housing for the brake oil cooler screen on machines with standard retarding Illustration 154 g01917944 (2) Housings for the brake oil cooler screens on machines with additional retarding . “Prepare the Machine for Maintenance”. attach the body (bed) retaining cables to the rear tow points. Prepare the machine for maintenance.

Reduce the engine speed to an idle. 2. Braking System . compare the previous engine rpm and the recent engine rpm. If necessary. Check the oil level in the hoist/brake tank. Remove the spring and remove the screen from the housing. During the test of the brakes.148 Maintenance Section Braking System . Move the transmission control to the D position. Test the brakes on a dry. Start the engine and operate the engine at an idle. Remove the cover from the screen housing . 8. i03450700 Illustration 155 g01961534 Service Brake Holding Ability Test 1. 7. and in the brake holding ability. If the seal is damaged. Fasten the seat belt before you test the brakes. 8. Install the cover. add oil. Check the area around the machine. The following tests are used to determine if the service brake system. 7. 6. 5. the secondary brake system. Make sure that the machine is clear of personnel and clear of obstacles. etc. level surface. NOTICE If the machine moved while testing the brakes. . Stop the engine. For the proper procedure. The machine should not move. Have the dealer inspect and. replace the seal with a new seal.Test SEBU8406-04 2. refer to Operation and Maintenance Manual. Inspect the seal in the housing. Depress service brake control (1) in order to apply the service brakes. in the power train efficiency. Remove the drain plug and drain the oil into a suitable container. Gradually increase the engine speed to 1300 rpm. “Hoist and Brake Tank Oil Level .Test SMCS Code: 4251-081. If this machine is equipped with additional retarding. 6. 4. Start the engine. 3. repair the service brake before returning the machine to operation. if necessary. and the parking brake system are functional. These tests are not intended to measure the maximum brake holding effort. repeat step 2 through 5 for the other brake oil cooler screen. This will determine the system deterioration. contact your Caterpillar dealer. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine. Fasten the seat belt before you test the brakes. If the machine begins to move during testing. Move the transmission control to the P position. 3. Install the clean screen and the spring. reduce the engine speed immediately and place the transmission control in the P position in order to engage the parking brake. 4. Secondary Brake Holding Ability Test 1. Check for leaks and make any necessary repairs. 4267-081 Personal injury can result if the machine moves during testing.Check”. The variations are the differences in the engine setting. Clean the screen in clean nonflammable solvent. 5.

contact your Caterpillar dealer. Make sure that the machine is clear of personnel and clear of obstacles. Gradually increase the engine speed to 1300 rpm. 6. Stop the engine.SEBU8406-04 149 Maintenance Section Braking System . 7. 8. Move the transmission control to the P position. Move the transmission control to the D position. Reduce the engine speed to an idle. Gradually increase the engine speed to 1300 rpm. The machine should not move. repair the parking/secondary brakes before returning the machine to operation.Test 2. Test the brakes on a dry. level surface. Start the engine. NOTICE If the machine moved while testing the brakes. repair the parking/secondary brakes before returning the machine to operation. 3. 4. 3. Move the transmission control to the P position. Reduce the engine speed to an idle. contact your Caterpillar dealer. 6. 5. Depress secondary brake control (2) in order to apply the secondary brakes. Move the transmission control to the D position. While both buttons are depressed. . Fasten the seat belt before you test the brakes. Check the area around the machine. The machine should not move. Start the engine. Have the Caterpillar dealer inspect and. NOTICE If the machine moved while testing the brakes. Stop the engine. Have the Caterpillar dealer inspect and. 4. if necessary. depress button (3) for the high gear limit RAISE and depress button (4) for the high gear limit LOWER at the same time. Note: The buttons can now be released and the parking brake will remain on. 2. Make sure that the machine is clear of personnel and clear of obstacles. level surface. Parking Brake Holding Ability Test 1. Check the area around the machine. g01519336 Illustration 156 5. 8. if necessary. Test the brakes on a dry. 7. When the transmission control is in the P position.

4050-510-BRE Note: In order to access the breather. it may be necessary to use a portable access system (ladder. Note: In order to access the breather. Use caution when working between the wheels and the frame. it may be necessary to use a portable access system (ladder. Breather (Front Axle) . or other portable access system) that is suitable and compliant to local regulations. stair assembly.Replace SMCS Code: 3282-510-BRE. Prepare the machine for maintenance. 3. Remove breather (1) from each front wheel.Replace SEBU8406-04 i03452901 i03454800 Breather (Differential and Final Drive) . . 3.150 Maintenance Section Breather (Differential and Final Drive) . “Prepare the Machine for Maintenance”. The steering system is hydraulically controlled and wheels can crush personnel during movement. or other portable access system) that is suitable and compliant to local regulations. If the wheels must be turned. 4251-510-BRE Personal injury or death can occur if personnel are trapped between the wheel and the frame. Install a new final drive breather. man lift. Remove final drive breather (1). man lift. “Prepare the Machine for Maintenance”. Illustration 158 g01799459 1. Refer to Operation and Maintenance Manual. Illustration 157 g01798053 1. Refer to Operation and Maintenance Manual. 2. stair assembly. Install a new breather on each front wheel. Prepare the machine for maintenance. ensure that all personnel are clear of the machine before any movement. 2.Replace SMCS Code: 3258-510-BRE.

Remove the truck body retaining cable and lower the body. man lift. Refer to Operation and Maintenance Manual. use a portable access system (ladder. . 5057-510-BRE When it is necessary to work under the machine with the body (bed) raised. Remove fuel tank breather (1). attach the body (bed) retaining cables to the rear tow points. or other portable access system) that is suitable and compliant to local regulations. Install the rear tow point pins through the ends of the retaining cables. Refer to Operation and Maintenance Manual. In order to access the breather with the dump body in the DOWN position. 1. “Prepare the Machine for Maintenance”. Install a new fuel tank breather. Failure to properly secure the body (bed) may result in personal injury or death.Replace When it is necessary to work under the machine with the body (bed) raised. stair assembly.SEBU8406-04 151 Maintenance Section Breather (Fuel Tank) . Note: The breather may also be accessed with the dump body in the DOWN position. 3. i04340083 Breather (Hoist and Brake Tank) . SMCS Code: 5056-510-BRE. Note: The breather may also be accessed with the dump body in the DOWN position. or other portable access system) that is suitable and compliant to local regulations. man lift. Illustration 159 g01798273 2. Secure the dump body in the fully raised position and prepare the machine for maintenance. attach the body (bed) retaining cables to the rear tow points. use a portable access system (ladder.Replace SMCS Code: 1273-510-BRE 4. Secure the dump body in the fully raised position and prepare the machine for maintenance. “Prepare the Machine for Maintenance”. 1. In order to access the breather with the dump body in the DOWN position. stair assembly. Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.Replace i04339961 Breather (Fuel Tank) .

152 Maintenance Section Breather (Steering Tank) . 3101-510-BRE Breather (Steering Tank) Replace SMCS Code: 4332-510-BRE 1. i03454883 Breather (Torque Converter and Transmission) . Remove the truck body retaining cable and lower the body. Refer to Operation and Maintenance Manual.Replace SMCS Code: 3030-510-BRE. “Prepare the Machine for Maintenance”. Remove steering tank breather (1). Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death. Note: The breather may also be accessed with the dump body in the DOWN position. Remove breather (1) for the hoist/brake tank. Install a new steering tank breather. 1. 4. “Prepare the Machine for Maintenance”. Illustration 160 g01797934 i04339982 2. Prepare the machine for maintenance. man lift. .Replace SEBU8406-04 Illustration 161 g01799495 2. Install a new breather for the hoist/brake tank. attach the body (bed) retaining cables to the rear tow points. When it is necessary to work under the machine with the body (bed) raised. Secure the dump body in the fully raised position and prepare the machine for maintenance. use a portable access system (ladder. Refer to Operation and Maintenance Manual. or other portable access system) that is suitable and compliant to local regulations. stair assembly. 3. In order to access the breather with the dump body in the DOWN position. 3.

SEBU8406-04 153 Maintenance Section Cab Air Filter . 7342-070. Illustration 163 g02100201 The filter element for the cab is located inside the operator station. Remove the truck body retaining cable and lower the body. install a new filter element. Allow the filter element to air dry. Remove cover (2) and filter element (1). 5. Prepare the machine for maintenance. 4. 3. install a new filter element. Tighten the retaining screws. Install a new torque converter and transmission breather. The operator's seat has been removed for ease of viewing. Remove torque converter and transmission breather (1). 1. Note: When rips or tears are noticed in the filter element. Loosen retaining screws (3). When a reduction of air circulation is noticed in the cab after cleaning the filter element. 7311-510-FI.Clean/Replace i03855636 Cab Air Filter . 3. . 4. Rinse the filter element in clean water.Clean/Replace SMCS Code: 7311-070-FI. 7342-510 Illustration 162 Shown with the dump body in the raised position g01923575 2. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. Wash the filter element in a nonsudsing detergent. Install the clean filter element and the cover. 2.

“Prepare the Machine for Maintenance”. Inspect the cable for damage and do not use a cable that is damaged. Refer to Special Publication. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specifications section. Prepare the machine for maintenance. Consult your Caterpillar dealer for proper replacement parts. replace the appropriate parts. Avoid contact with skin and eyes. Dispose of all fluids according to local regulations and mandates. NENG2500. “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. Inspect the retaining cable for any of the following conditions: Cooling System Coolant (ELC) . . testing. i04032116 Cable (Truck Body Retaining) . steam and alkali. Wear gloves when handling the cable. The radiator and all lines to heaters or the engine contain hot coolant or steam. 2. At operating temperature. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Inspect SMCS Code: 5154-040. Use of a damaged cable could result in personal injury or death. • Reduction in the diameter • Broken wires • Worn wires • Corroded wires • Loose strands or loose wires • Loose cable ends or separation between the cable and the cable end • Kinks • Cuts • Flat spots 3. engine coolant is hot and under pressure. 1. Inspect the retaining pins and locking hardware for any of the following conditions: • Distortion such as bends or twists . the hose can come off causing burns. 7258-040-KA A raised body (bed) may fall unexpectedly if a damaged cable is used. Refer to Operation and Maintenance Manual. 1395-044-NL Personal injury can result from hot coolant.154 Maintenance Section Cable (Truck Body Retaining) . adjusting. maintenance.Change SMCS Code: 1350-044-NL. Cooling System Coolant Additive contains alkali. Any contact can cause severe burns.Inspect SEBU8406-04 i03655302 • Wear • Corrosion • Cracks or gouges If any of the above conditions exist. Do not attempt to tighten hose connections when the coolant is hot. and repair of the product. Inspect the retaining cable ends and the cable connection for the truck body for any of the following conditions: • Distortion such as bends or twists • Wear • Corrosion • Cracks or gouges 4.

SEBU8406-04 155 Maintenance Section Cooling System Coolant (ELC) . “Prepare the Machine for Maintenance”. This will relieve system pressure. refer to Operation and Maintenance. Illustration 164 g01899554 2. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. Illustration 165 g01899555 3. This machine was factory filled with Cat Extended Life Coolant. Use only Cat Extender with Cat ELC. Refer to Operation and Maintenance Manual. Failure to follow these recommendations could result in damage to the cooling systems components. 1. Drain the coolant into a suitable container. Remove the filler cap.Change NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination. . Open drain valve (2). Change the coolant whenever the coolant is dirty or whenever foaming is observed. Close the drain valve. Slowly loosen filler cap (1). If ELC cooling system contamination occurs. Change the coolant during scheduled maintenance intervals. Prepare the machine for maintenance.

steam and alkali. and air is purged from the system.Add SMCS Code: 1352-538-NL Illustration 166 g02216894 4. Stop the engine and drain the cleaning solution into a suitable container. Install a 88. Start the engine without the filler cap. c. i03571658 Cooling System Coolant Extender (ELC) . Drain the coolant into a suitable container. perform the following procedures during initial start-up: a. 5. Cooling System Coolant Additive contains alkali. 12. “Cooling System Coolant Level Check”. 9.156 Maintenance Section Cooling System Coolant Extender (ELC) . SEBU6250. 7. b. At operating temperature. Close the drain valve. increase the engine speed to a high idle until the thermostat is open and the coolant level is stabilized. “Cooling System Specifications” and Operation and Maintenance Manual.50 inch) long NPT pipe nipple in order to open the internal drain valve. 10. . Start the engine and operate the engine for 90 minutes. engine coolant is hot and under pressure. Refer to Operation and Maintenance Manual. Note: If you are using Caterpillar antifreeze. the hose can come off causing burns. Run the engine at low idle for 10 minutes. Remove the pipe nipple. flush the system with water until the draining water is clear. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). Personal injury can result from hot coolant. Then. Flush the water into a suitable container. When the engine is stopped. Clean the drain plug and install the drain plug. Install the filler cap. Any contact can cause severe burns. 8. Refer to Special Publication. d. Add the coolant solution. “Capacities (Refill)”.Add SEBU8406-04 11. 6. Do not attempt to tighten hose connections when the coolant is hot. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Fill the system with clean water and a 6 to 10% concentration of cooling system cleaner. After the cooling system has been filled. Avoid contact with skin and eyes.0 mm (3. Remove drain valve plug (3) on the lower coolant line for the oil coolers. The radiator and all lines to heaters or the engine contain hot coolant or steam. do not add the supplemental coolant additive at this time and/or change the element at this time. Maintain the coolant at the proper level as the thermostat opens.

refer to Operation and Maintenance. Clean the filler cap and inspect the filler cap. adjusting and repair of the product. SEBU6250. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 5. maintenance. Remove the filler cap. Refer to Operation and Maintenance Manual. 7. Start the engine and check for leaks. Check coolant level gauge (2). when shipped from the factory unless special requirements are defined. 4. NENG2500. 6. If necessary. or shipped to. Refer to the table in Special Publication. If ELC cooling system contamination occurs. Refer to Special Publication. “Cooling System Specification” for the cooling system requirements. This machine was factory filled with Cat Extended Life Coolant. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. “Extended Life Coolant (ELC)”. Note: Make sure that the coolant is drained into a suitable container. NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination. Install the filler cap. NOTICE Excessive additive (greater than the recommended 6% initial fill) together with concentrations of antifreeze greater than 60% cause deposits to form and can result in radiator tube blockage and overheating. 3. Allow the engine to cool before adding coolant. Failure to follow these recommendations could result in damage to the cooling systems components.Add NOTICE Adding coolant to an overheated engine could result in damage to the engine. Refer to Special Publication. testing.SEBU8406-04 157 Maintenance Section Cooling System Coolant Extender (ELC) . SEBU6250. drain enough coolant in order to allow the addition of the liquid coolant additive. “Prepare the Machine for Maintenance”. Loosen filler cap (1) slowly in order to relieve pressure. Prepare the machine for maintenance. Dispose of all fluids according to local regulations and mandates. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. add premixed coolant in order to bring the coolant in the green range on the coolant level gauge. an area with freezing temperatures. the cooling system must be protected to the lowest outside (ambient) temperature. Allow the coolant level to stabilize. . 1. The engine cooling system is normally protected to a minimum of−29°C (−20°F) with Caterpillar Antifreeze. This table lists the correct amount of Caterpillar Extended Life Coolant (ELC) extender that should be added to the cooling system. Use 8T-5296 Test Kit in order to check the concentration. If the machine is to be stored in. Illustration 167 g01899597 2. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. If necessary. Use only Cat Extender with Cat ELC.

an area with freezing temperatures. when shipped from the factory unless special requirements are defined. NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination. “Cooling System Coolant Extender (ELC) . 1. Cooling System Coolant Additive contains alkali. allow the engine to cool and loosen filler cap (2) slowly. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Allow the engine to cool before adding coolant.Check SEBU8406-04 i03571727 Cooling System Coolant Level . Avoid contact with skin and eyes. Then add premixed coolant in order to bring the coolant in the green range on the coolant level gauge. NOTICE Adding coolant to an overheated engine could result in damage to the engine. The engine cooling system is normally protected to a minimum of−29°C (−20°F) with Caterpillar Antifreeze. If the machine is to be stored in. or shipped to. Illustration 168 g01899933 If coolant needs to be added daily. The needle should be in the green range. the cooling system must be protected to the lowest outside (ambient) temperature.Add” for more information. . “Prepare the Machine for Maintenance”. steam and alkali. If ELC cooling system contamination occurs. If the gauge indicator is in the red range. The radiator and all lines to heaters or the engine contain hot coolant or steam. 3. check for leaks. At operating temperature. Prepare the machine for maintenance. Do not attempt to tighten hose connections when the coolant is hot. the hose can come off causing burns. Any contact can cause severe burns. refer to Operation and Maintenance. This machine was factory filled with Cat Extended Life Coolant. engine coolant is hot and under pressure.158 Maintenance Section Cooling System Coolant Level . Refer to Operation and Maintenance Manual. 2. Failure to follow these recommendations could result in damage to the cooling systems components. Use only Cat Extender with Cat ELC. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. Use coolant level gauge (1) in order to check the coolant levels. Refer to Operation and Maintenance Manual.Check SMCS Code: 1350-535-FLV Personal injury can result from hot coolant.

Supplies for collecting samples can be obtained from your Caterpillar dealer. you must establish a consistent trend of data. man lift. In order to receive the full effect of S·O·S analysis. Refer to Operation and Maintenance Manual. “S·O·S Services Analysis” Good S·O·S Sample” • Special Publication. Hot coolant and hot components can cause severe burns. “S·O·S Services: Understanding Your Results” Analysis” • Special Publication. Take the oil sample when the engine is cool and when the engine is operating at low idle. Obtain S·O·S samples as close as possible to the recommended sampling interval. PEGJ0046. Do not allow hot coolant or hot components to contact the skin. Illustration 169 g01901074 . Note: In order to access the sampling valve. Submit the sample for Level 1 S·O·S analysis. Supplies for collecting samples can be obtained from your Caterpillar dealer.Obtain SMCS Code: 1350-008. Note: In order to access the sampling valve.Obtain SMCS Code: 1350-008. Refer to the following publications for S·O·S information: At operating temperature. PEHJ0191. stair assembly. In order to establish a pertinent history of data. Obtain a coolant sample through sampling valve (1). 7542 2. it may be necessary to use a portable access system (ladder. 3. or other portable access system) that is suitable and compliant to local regulations. “Caterpillar Machine Fluids Recommendations”. PEGJ0047. “S·O·S Information” • Special Publication. Note: Level 1 results may indicate a need for Level 2 Analysis. perform consistent samplings that are evenly spaced. SEBU6250. Prepare the machine for maintenance. “Prepare the Machine for Maintenance”. it may be necessary to use a portable access system (ladder. Prepare the machine for maintenance. “Prepare the Machine for Maintenance”.SEBU8406-04 159 Maintenance Section Cooling System Coolant Sample (Level 1) . 1. 1395-008.Obtain i03572135 Cooling System Coolant Sample (Level 1) . “S·O·S Fluid i03572143 Cooling System Coolant Sample (Level 2) . • Operation and Maintenance Manual. engine coolant is hot and under pressure. 7542 At operating temperature. perform consistent samplings that are evenly spaced. stair assembly. In order to establish a pertinent history of data. Refer to Operation and Maintenance Manual. Hot coolant and hot components can cause severe burns. you must establish a consistent trend of data. “How to Take a • Special Publication. man lift. In order to receive the full effect of S·O·S analysis. Do not allow hot coolant or hot components to contact the skin. or other portable access system) that is suitable and compliant to local regulations. engine coolant is hot and under pressure. 1395-008. Obtain S·O·S samples as close as possible to the recommended sampling interval. 1.

for foreign material. Any contact can cause severe burns. Obtain a coolant sample through sampling valve (1). Prepare the machine for maintenance. steam and alkali. 1382-510 Personal injury can result from hot coolant. SEBU6250. and for deposits. Illustration 170 g01901085 2. Refer to Operation and Maintenance Manual. 3. Do not attempt to tighten hose connections when the coolant is hot. “S·O·S Fluid Illustration 171 g01901087 2. 4. if necessary. 3. “S·O·S Information” • Special Publication. The radiator and all lines to heaters or the engine contain hot coolant or steam. 5. Avoid contact with skin and eyes. PEHJ0191.160 Maintenance Section Cooling System Pressure Cap . Install the filler cap. PEGJ0046. “Caterpillar Machine Fluids Recommendations”. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. “S·O·S Services Analysis” Good S·O·S Sample” • Special Publication. Inspect the filler cap for damage. Take the oil sample when the engine is cool and when the engine is operating at low idle. Clean the filler cap with a clean cloth or replace the filler cap. the hose can come off causing burns. Refer to the following publications for S·O·S information: • Operation and Maintenance Manual. “How to Take a • Special Publication. Remove filler cap (1) slowly in order to relieve the pressure.Clean/Replace SEBU8406-04 i03572146 Cooling System Pressure Cap . . PEGJ0047. 1. “Prepare the Machine for Maintenance”. Cooling System Coolant Additive contains alkali. Submit the sample for Level 2 S·O·S analysis. “S·O·S Services: Understanding Your Results” Analysis” • Special Publication.Clean/Replace SMCS Code: 1382-070. engine coolant is hot and under pressure. At operating temperature.

seal. 5. Illustration 172 g01901093 2. If necessary. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. If the system overheats or if coolant is leaking. engine coolant is hot and under pressure. Prepare the machine for maintenance. replace any damaged parts. Prepare the machine for maintenance. Damage to the crankshaft vibration damper or failure of the damper can increase torsional vibrations.SEBU8406-04 161 Maintenance Section Cooling System Relief Valve . Refer to Operation and Maintenance Manual. Do not attempt to tighten hose connections when the coolant is hot. i04382949 Damper (Crankshaft) . 2. Illustration 173 (3) (4) (5) (6) (7) Gaskets Mounting bolts Seal Relief valve Cover plate g01428758 4. steam and alkali. mounting bolts. Remove the mounting bolts from relief valve assembly (2) and remove the relief valve assembly. Install the relief valve assembly.Inspect SMCS Code: 1205-040 The crankshaft vibration damper limits the torsional vibration of the crankshaft. A deteriorating damper can cause excessive power train noise at variable points in the speed range. This vibration can result in damage to the crankshaft and to other engine components. 3. Refer to Operation and Maintenance Manual. “Prepare the Machine for Maintenance”. mounting bolts. Any contact can cause severe burns. 7. relief valve. Visually inspect the damper for the following conditions: • dents • cracks . Clean all debris and deposits from the following: gaskets. relief valve. Inspect the following: gaskets. The radiator and all lines to heaters or the engine contain hot coolant or steam. the hose can come off causing burns. 1. clean the relief valves or replace the relief valves. 6. 1. seal. Avoid contact with skin and eyes. Cooling System Coolant Additive contains alkali. Install the filler cap. and cover plate. Remove filler cap (1) slowly in order to relieve the pressure. “Prepare the Machine for Maintenance”. At operating temperature. The visconic damper has a weight that is located inside a fluid filled case. and cover plate.Clean i03572148 Cooling System Relief Valve Clean SMCS Code: 1370-070 Personal injury can result from hot coolant.

The temperature should not reach 93 °C (200 °F). refer to Operation and Maintenance Manual. and smooth characteristics.Remove and Install”. 4050 The oil change interval for the differential and final drives can be monitored with a S·O·S (Scheduled Oil Sampling) program. “S·O·S Information”. “Prepare the Machine for Maintenance”. KENR8393. Silicone has transparent. the oil change interval is based on the following: • evidence of excessive heat (an infrared 3. replace the crankshaft vibration damper. Refer to Operation and Maintenance Manual. KENR8578.Change SMCS Code: 3258. Prepare the machine for maintenance. “Prepare the Machine for Maintenance”.) thermometer can be used to monitor the temperature of the damper during operation. i03572413 Differential and Final Drive Oil . If any of these conditions exist. . Prepare the machine for maintenance.Check SMCS Code: 3258. 2. Refer to Testing and Adjusting. “Damper . For the replacement of the crankshaft vibration damper. For more information on S·O·S services. 3260. refer to Disassembly and Assembly. When a S·O·S program is used. 2. “793F Engine Supplement”. 3284 Illustration 175 g01902137 1. Rotate the wheels so that final drive drain plug (1) is in the lowest position on the rear wheel.Check SEBU8406-04 • bends • evidence of a fluid leak (The fluid in the damper is silicone. “Differential and Bevel Gear Adjust” for the adjustment procedure for the thrust pin. i04030014 • The condition of the oil • The S·O·S recommendation Differential Thrust Pin Clearance .162 Maintenance Section Differential Thrust Pin Clearance . viscous. Refer to Operation and Maintenance Manual. Illustration 174 (1) Cover for the thrust pin g02217373 1. “793F Power Train”.

Refer to Operation and Maintenance Manual. perform the procedures in Operation and Maintenance Manual. Check the differential compartment and the final drive compartment for the proper fluid level.SEBU8406-04 163 Maintenance Section Differential and Final Drive Oil . For the proper procedure. adjusting and repair of the product. “Differential and Final Drive Oil . “Capacities (Refill)”. Install a 100 mm (4 inch) long NPT pipe nipple in order to open the internal drain valve. Check the oil level. Illustration 176 g01902134 6. Operate the machine on level ground for a few minutes. Before the differential and final drives are filled. “Differential and Final Drive Oil . Remove the final drive drain plug. 4. refer to Operation and Maintenance Manual. Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. Note: Inspect any magnetic plugs and the used oil. 12. Fill the differential compartment through port (4). adjust the oil level to the bottom of the sight gauge. Note: The final drives may need to be repositioned in order to place the final drive drain plug in the lowest position. . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 8. Correct oil levels are critical in the differential and final drives. Clean the drain plug. After the oil has been changed in the differential and final drives. 5. adjustment of the oil level may be necessary when the truck reaches operating temperature. Drain the oil into a suitable container. NOTICE If the ambient temperature at engine start-up or during operation is below −10°C (14°F). Remove drain valve plug (3). Fill the differential compartment to the bottom of sight gauge (5). “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Fill each final drive to the bottom of the filler plug opening.Check”. Remove final drive filler plugs (2). The outer diameter of the NPT pipe nipple must be 38 mm (1. Note: Allow oil to fill all of the compartments.Inspect” for further information. Remove differential drain plug (3) and allow the oil to drain into a suitable container. maintenance. the final drive filler plug will be at the correct oil level. 14. Refer to illustration 175. 3. Park the machine according to the guidelines in Operation and Maintenance Manual. Check for leaks and make any necessary repairs. testing.5 inch). Failure to warm up the oil or improper lubrication levels prior to operation will cause damage to the machine. Clean the drain plug. refer to Operation and Maintenance Manual.Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Dispose of all fluids according to local regulations and mandates. Install the drain plug. 13. Drain the oil into a suitable container. 11. 9. 15. “Prepare the Machine for Maintenance”. 10. If necessary. Refer to Special Publication. 7. When the final drive drain plug is in the lowest position. “Lubricant Viscosities” and Operation and Maintenance Manual. NENG2500. Repeat Step 1 through Step 4 for the other final drive. Install the drain plug. Maintain the proper oil level for the differential to the bottom of the sight gauge . “Differential Warm-up and Break-in”.

Unless a symptom of an obvious failure appears. Correct oil levels are critical in the differential and final drives. If the differential and final drive oil has any of the above symptoms. 3. “Prepare the Machine for Maintenance”.164 Maintenance Section Differential and Final Drive Oil . i03656917 Differential and Final Drive Oil . 4050 Correct oil levels are critical in the differential and final drives. Maintain the oil level at the bottom of the sight gauge. Refer to Operation and Maintenance Manual. do not adjust or inspect the rear wheel bearings. Prepare the machine for maintenance. The differential and final drive oil level needs to be checked and maintained at operating temperature. Differential and Final Drive Oil Sample . Inspect the differential and final drive oil for any of the following symptoms that may indicate a mechanical failure: • Discoloration and change in viscosity • A high amount of metal on the magnetic plug • Oil leaks in the area around the drive wheel bearings Illustration 177 g01902993 2. “Prepare the Machine for Maintenance”. Do not allow hot oil or hot components to contact the skin. 1. If the oil level is checked cold. Check the oil level after repairs and after maintenance. i04030230 • Review the latest results and trends from the S·O·S samples The rear wheel bearings do not need to be adjusted or inspected until the scheduled overhaul. Check the oil level prior to operation.Obtain SMCS Code: 3258-008. . Use sight gauge (1) to check the oil level for the differential and final drives. Use port (2) to add oil. 4050-008. Note: Overfilling the differential and final drives will cause overheating and foaming of the oil in long hauling applications and high speed applications. adjustment of the oil level may be necessary when the truck reaches operating temperature. the rear wheel bearings may need to be inspected.Check SMCS Code: 3258. A reduction of the life of components may be the result of overheating and foaming of the oil. 4070-008. A reduction of the life of components may be the result of overheating and foaming of the oil.Inspect SMCS Code: 4208 1. Refer to Operation and Maintenance Manual. i03573292 Differential and Final Drive Oil Level . Allow the oil to fill all of the compartments before rechecking the oil level. add oil. Consult your Caterpillar dealer for more information.Inspect SEBU8406-04 Note: Overfilling the differential and final drives will cause overheating and foaming of the oil in long hauling applications and high speed applications. 7542 Hot oil and hot components can cause personal injury. If necessary. 4. Prepare the machine for maintenance. 2.

In order to maintain sufficient vision. PEHJ0191. 3. 7348-070 The Work Area Vision System (WAVS) and the Cat Detect Object Detection system both utilize multiple cameras and a display. Illustration 179 WAVS display 2.Clean Obtain S·O·S samples as close as possible to the recommended sampling interval. Refer to Operation and Maintenance Manual. Obtain the differential and final drive oil sample through sampling valve (1) that is located on the base of the rear axle oil filter. Illustration 178 g01904153 g01223034 The left rear tires and wheels have been removed for ease of viewing. Prepare the machine for maintenance. Supplies for collecting samples can be obtained from your Caterpillar dealer.Clean (If Equipped) SMCS Code: 7347-070. “S·O·S Services Analysis” Good S·O·S Sample” • Special Publication. “S·O·S Fluid i04218936 Display and Camera . Take the oil sample when the engine is running at an idle. perform consistent samplings that are evenly spaced. • Operation and Maintenance Manual. SEBU6250. “S·O·S Services: Understanding Your Results” Analysis” • Special Publication. “Prepare the Machine for Maintenance”. In order to receive the full effect of S·O·S analysis. Refer to Operation and Maintenance Manual. 1. 1. “Caterpillar Machine Fluids Recommendations”. keep the camera lens and the display clean. In order to establish a pertinent history of data. a consistent trend of data must be established. The engine must be running in order to drive the lubrication pump for the rear axle. Refer to the following publications for S·O·S information: .SEBU8406-04 165 Maintenance Section Display and Camera . PEGJ0047. Prepare the machine for maintenance. Submit the sample for S·O·S analysis. “How to Take a • Special Publication. PEGJ0046. “S·O·S Information” • Special Publication. “Prepare the Machine for Maintenance”.

Dispose of all fluids according to local regulations and mandates. For more information on WAVS. Refer to Special Publication. “Prepare the Machine for Maintenance”. “793F Off-Highway Truck Power Train” or consult your Cat dealer. Drive Shaft Spider and Bearing . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. The display has a soft plastic surface that can be easily damaged by an abrasive material.Replace SMCS Code: 3253-510 1. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Use a damp cloth or water spray in order to clean the camera lens. KENR8397. snow. . “793F Off-Highway Truck Power Train” or consult your Cat dealer. Secure the dump body in the fully raised position and prepare the machine for maintenance.Replace SEBU8406-04 i04337413 Drive Shaft Slip Joint . The display is not sealed. Refer to Operation and Maintenance Manual. refer to Operation and Maintenance Manual. or ice. adjusting and repair of the product.Change (If Equipped) SMCS Code: 5713-044-OC NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Note: The camera is equipped with an internal heater to help counteract the effects of condensation. Refer to Operation and Maintenance Manual. refer to Operation and Maintenance Manual.166 Maintenance Section Drive Shaft Slip Joint . i04337410 Illustration 180 Cat Detect Object Detection display g02217954 2. For information on removing the drive shaft (slip joint). damp cloth in order to clean the display. “Cat Detect Object Detection”. NENG2500. “Camera”. 2. Use a soft. i03829310 Illustration 181 g01223051 The camera for WAVS and the Cat Detect Object Detection system . The camera is not affected by high-pressure spray. Do not immerse the display with liquid.Replace SMCS Code: 3251-510 1. For more information on Cat Detect Object Detection system. Electric Drive Pump (Powered Stairway) Oil . refer to Disassembly and Assembly . Secure the dump body in the fully raised position and prepare the machine for maintenance. KENR8397. 2. refer to Disassembly and Assembly . 3. “Prepare the Machine for Maintenance”. maintenance. testing. The camera is a sealed unit. For information on removing the spider assembly for the drive shaft.

Refer to Operation and Maintenance Manual. i03828309 Electric Drive Pump (Powered Stairway) Oil Level . 6.SEBU8406-04 167 Maintenance Section Electric Drive Pump (Powered Stairway) Oil Level . Use a suction device in order to extract the oil through the filler neck. Remove tread plate (1) from the platform of the powered stairway. The oil level for the powered stairway is visible through the clear plastic oil reservoir (3). Illustration 184 g02078415 2. Note: Do not operate the powered stairway when the oil volume is below minimum level (5). . Refer to Operation And Maintenance Manual. Remove filler cap (2) for the reservoir. “Capacities (Refill)”. If necessary. 5. Maintain the oil volume at the full level (4). “Prepare the Machine for Maintenance”. Illustration 185 g02078418 3.Check (If Equipped) SMCS Code: 5713-535-FLV 1. 4. 5.Check 1. Illustration 183 g02079313 3. Remove tread plate (1) from the platform of the powered stairway. Prepare the machine for maintenance. remove filler cap (3) and add oil. Refer to Operation And Maintenance Manual. Refer to Operation and Maintenance Manual. Fill the reservoir for the powered stairway to full level (4). “Lubricant Viscosities”. The oil level for the powered stairway is visible through the clear plastic oil reservoir (2). “Prepare the Machine for Maintenance”. Prepare the machine for maintenance. 4. Illustration 182 g02078415 2.

and the Advisor display will provide a message regarding the specific problem. or other portable access system) that is suitable and compliant to local regulations. Install clean primary air filter elements. Install the covers for the air filter housings. Air pressure must not exceed 207 kPa (30 psi). 1054-510-PY NOTICE Service the air cleaner only with the engine stopped. Refer to Operation and Maintenance Manual. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life.Clean/Replace SMCS Code: 1051-070-PY. Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers. stair assembly. 4.Clean/Replace SEBU8406-04 i04030065 Engine Air Filter Primary Element . Direct the air flow up the pleats and down the pleats from the inside of the filter element. Note: In order to access the air filter elements. it may be necessary to use a portable access system (ladder. Use low pressure compressed air in order to remove the dust from the filter element. 1. Note: This machine is equipped with ultra high efficiency (primary) air filter elements. 6. 5. Wear the proper personal protection equipment when pressurized air is used. 1054-070-PY. Take extreme care in order to avoid damage to the pleats. The engine fault indicator will activate when there is an inlet air restriction. gaskets. “Monitoring System” for further information. Illustration 186 Location of the air filter housings. 1051-510-PY. Dirt entering the engine will cause damage to engine components. 3.168 Maintenance Section Engine Air Filter Primary Element . g01903474 Do not wash the filter element. The engine fault indicator is located inside the cab. Refer to Operation and Maintenance Manual. Prepare the machine for maintenance. or seals. Remove covers (1) for the air filter housings. Illustration 187 g01217472 2. Do not use air filters with damaged pleats. Service the air cleaner filter element when the engine fault indicator is activated. . “Prepare the Machine for Maintenance”. Clean the dust valves on the bottom for the air filter housings. Engine damage could result. Clean the inside of the air filter housings. Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Remove primary filter elements (2) from the air filter housings. man lift.

Do not aim the stream of air directly at the primary air filter element. Do not use a primary air filter element that has any tears and/or holes in the filter material. Use filtered. the gaskets. gaskets. . The primary air filter element should be replaced at least one time per year.Replace SMCS Code: 1054-510-SE NOTICE Always replace the secondary element. dry primary air filter element. When the primary air filter element is cleaned. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Rotate the primary air filter element. Do not attempt to reuse it by cleaning. Cleaning with pressurized air is recommended prior to vacuum cleaning. Discard damaged primary air filter elements. Do not use a primary air filter element with damaged pleats. Inspect the primary air filter element for light that may show through the filter material. Pressurized air will not remove deposits of carbon and oil. i03574580 Illustration 188 g00281692 Note: When the primary air filter elements are cleaned. Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats.Replace The primary air filter element can be used up to six times if the element is properly cleaned and the element is properly inspected. Use a 60W blue light in a dark room or in a similar facility. Visually inspect the primary air filter elements before cleaning.SEBU8406-04 169 Maintenance Section Engine Air Filter Secondary Element . and the outer cover. Engine damage could result. If it is necessary in order to confirm the result. Place the blue light in the primary air filter element. dry air with a maximum pressure of 207 kPa (30 psi). dusty environment. Illustration 189 g00281693 Inspect the clean. or seals. This replacement should be performed regardless of the number of cleanings. check for rips or tears in the filter material. Inspect the air filter elements for damage to the seal. Vacuum cleaning will not remove deposits of carbon and oil. Engine Air Filter Secondary Element . compare the primary air filter element to a new primary air filter element that has the same part number. Dirt could be forced further into the pleats. There are two common methods that are used to clean primary air filter elements: Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry. Inspect the primary air filter element for tears and/or holes. Inspecting the Primary Air Filter Elements • Pressurized air • Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times.

Refer to Operation and Maintenance Manual. Remove secondary filter elements (1) and properly discard the secondary elements. Prepare the machine for maintenance. stair assembly. Refer to Operation and Maintenance Manual. 3. Cover the air inlet openings. 4. 2. “Prepare the Machine for Maintenance”. 6. Clean the lower precleaner bowl and the dust valve with air pressure. or other portable access system) that is suitable and compliant to local regulations. Loosen clamp (1) on the precleaner and remove lower precleaner bowl (2) and dust valve (3). Uncover the air inlet openings. 2. Install the new secondary filter elements. it may be necessary to use a portable access system (ladder. Install the primary filter elements and install the air filter covers. man lift. i03574742 Engine Air Precleaner . . man lift. 5. it may be necessary to use a portable access system (ladder. stair assembly.170 Maintenance Section Engine Air Precleaner . Note: In order to access the air filter elements. Illustration 190 (1) Secondary filter element g01903515 3. Remove the air filter covers and remove the primary filter elements from the air filter housings. Prepare the machine for maintenance. Paint will cause the rubber to harden and the rubber may not seal properly. 1. “Prepare the Machine for Maintenance”. or other portable access system) that is suitable and compliant to local regulations. 1.Clean SEBU8406-04 Note: Replace the engine air filter secondary elements when you service the engine air filter primary elements for the third time. g01180274 Illustration 192 Note: Do not paint dust valves (3). Clean the inside of the air cleaner housings. Replace the secondary filter elements if the exhaust smoke remains black and the clean primary filter elements have been installed. Perform the following procedure for each engine air precleaner.Clean SMCS Code: 1055-070 Illustration 191 g01903633 Note: In order to access the engine air precleaners.

The quantity of consumed fuel is a better indicator for the overhaul interval than service hours. • Fuel Priming Pump • Gear Train Bushings. Gaskets. Clean the tubes. 2. If the load factor is lower than 40 percent. Install New SMCS Code: 1000-012-IC. Install New 4.Clean/Inspect. Rebuild/Install Reman. 6. Rod Bearings. the number of service hours for the overhaul interval will be higher. and Crankshaft Thrust Plates • Piston Rings • Wiring Harness • Coolant Hoses • High Pressure Fuel Pump i03994010 Engine Components Clean/Inspect. The quantity of burned fuel that is shown with the service hours assumes a load factor of 40 percent. Rebuild/Install Reman. Repeat steps 2 through 5 for each precleaner. Refer to Operation and Maintenance Manual. 1000-571-IC 1. Make sure that all of the tubes within the precleaner are free of dirt. Bearings. Prepare the machine for maintenance. “Prepare the Machine for Maintenance”. and O-rings • Camshaft Bearings • Engine Mounts • Engine Software • Oil Pressure Regulating Valve • Fuel Pressure Regulating Valve . Install the clean lower precleaner bowl. the number of service hours for the overhaul interval will be lower. Consult your Caterpillar dealer for further information.SEBU8406-04 171 Maintenance Section Engine Components . if necessary. Engine damage can occur. and the clean dust valve and tighten the clamp on the precleaner. 5. Caterpillar recommends this additional maintenance for the following engine components. Refer to the Disassembly and Assembly manual and the Disassembly and Assembly supplement for the removal and installation of engine components. NOTICE Do not operate the machine with the dust valves removed. 1000-022-MC. and Thrust Plates • Main Bearings. If the load factor is higher than 40 percent. Rebuild Components and/or Install Remanufactured Components • Cylinder Heads • Turbochargers • Oil Cooler Cores • Oil Pump • Scavenge Oil Pump • Water Pumps • Starter(s) • Refrigerant Compressor • Wastegate (High Altitude Arrangement) (C175-20 797F Only) • Injectors • Air Compressor (If Equipped) Clean Components and Inspect Components for Reusability • Aftercooler • Camshaft • Camshaft Lifters • Connecting Rods • Crankshaft • Cylinder Block • Cylinder Liners • Damper Install New Components • All Seals.

The quantity of consumed fuel is a better indicator for the mid-life service interval than service hours. 6. 4. • Air Compressor (If Equipped) • Starter(s) • Alternator • High Pressure Fuel Pump • Fuel Priming Pump • Fuel Transfer Pump • Turbochargers (High Altitude Arrangement only) • Injectors • Refrigerant Compressor • Water Pumps • Coolant Hoses . The quantity of burned fuel that is shown with the service hours assumes a load factor of 40 percent. 5. the number of service hours for the mid-life service interval will be higher. One breather is on the right side of the flywheel housing and one breather is on the left side of the flywheel housing. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual. Prepare the machine for maintenance.172 Maintenance Section Engine Components . Remove the breathers from the hoses. Wash the breathers in clean nonflammable solvent. 3. If the load factor is lower than 40 percent. 2. If the load factor is higher than 40 percent. Remove bolts from the clamps at the base of the breathers. “Prepare the Machine for Maintenance”. 1. Consult your Caterpillar dealer for further information.Rebuild/Install Reman SEBU8406-04 • Gear Train • Piston Crowns and Piston Skirts • Piston Pins • Spacer Plates i03994009 i03575743 Engine Crankcase Breather Clean SMCS Code: 1317-070-ENG Engine Components Rebuild/Install Reman SMCS Code: 1000-022-MC 1. the number of service hours for the mid-life service interval will be lower. Refer to the Disassembly and Assembly manual and the Disassembly and Assembly supplement for the removal and installation of engine components. 2. Install the hoses and hose clamps on the breathers. Illustration 193 g01904537 The engine in this machine is equipped with two engine crankcase breathers (1) at the rear of the engine. “Prepare the Machine for Maintenance”. Tighten all of the clamps. Loosen the hose clamps. Install the clamps at the base of the breathers. Refer to Operation and Maintenance Manual. Caterpillar recommends this additional maintenance for the following engine components.

“Prepare the Machine for Maintenance”.Check i03575781 Engine Oil Level .SEBU8406-04 173 Maintenance Section Engine Oil Level . Illustration 194 g01557253 . 1. Either condition can cause engine damage.Check SMCS Code: 1348-535-FLV NOTICE Do not under fill or overfill engine crankcase with oil. Refer to Operation and Maintenance Manual. Prepare the machine for maintenance.

a. 1. PEGJ0046.Obtain SEBU8406-04 2. Supplies for collecting samples can be obtained from your Caterpillar dealer. or other portable access system) that is suitable and compliant to local regulations. Take the oil sample when the engine is operating at low idle. remove oil filler cap (1) and add oil. “How to Take a • Special Publication. “S·O·S Fluid i04032117 Engine Oil and Filter . 7542 Illustration 195 g01904619 Hot oil and hot components can cause personal injury. If the engine is running at an idle and the oil is at operating temperature. PEHJ0191. 3. Refer to Operation and Maintenance Manual. Prepare the machine for maintenance. it may be necessary to use a portable access system (ladder. 3. Do not allow hot oil or hot components to contact the skin. “S·O·S Services Analysis” Good S·O·S Sample” • Special Publication. PEGJ0047. perform consistent samplings that are evenly spaced. .Obtain SMCS Code: 1348-008. Clean the filler cap and install the filler cap. In order to establish a pertinent history of data. “Caterpillar Machine Fluids Recommendations”. Obtain S·O·S samples as close as possible to the recommended sampling interval. Obtain the engine oil sample through sampling valve (1) that is located on the oil lines on the left side of the engine. 1348-044 Hot oil and hot components can cause personal injury.174 Maintenance Section Engine Oil Sample . If necessary. “Prepare the Machine for Maintenance”. maintain the oil level in green range (A).Change SMCS Code: 1308-510. If the engine is stopped and the oil is cold. 2. 4. Note: In order to access the sampling valve. SEBU6250. “S·O·S Services: Understanding Your Results” Analysis” • Special Publication. stair assembly. Maintain the oil level within the green range on the sight gauge. “S·O·S Information” • Special Publication. In order to receive the full effect of S·O·S analysis. Do not allow hot oil or hot components to contact the skin. Submit the sample for S·O·S analysis. you must establish a consistent trend of data. man lift. maintain the oil level in green range (B). b. Refer to the following publications for S·O·S information: • Operation and Maintenance Manual. i03575920 Engine Oil Sample .

open drain valve (1) and drain the oil into a suitable container. Dispose of all fluids according to local regulations and mandates. Refer to Operation and Maintenance Manual. testing. Note: In order to access the oil filler tube and the oil filters. Prepare the machine for maintenance. Refer to Special Publication. 1. Remove drain plug (4) from the bottom of the crossover tube . stair assembly. adjusting. Close the drain valve after the oil is drained. Remove the oil drain hose after the oil is drained. Wash the drain plugs in clean nonflammable solvent and install the drain plugs. “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. a. 4.SEBU8406-04 175 Maintenance Section Engine Oil and Filter . remove the dust cover and attach the oil drain hose to male fitting (3) in order to drain the oil. Wash the drain plug in clean nonflammable solvent and install the drain plug.Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Drain the oil into a suitable container. Replace a damaged seal with a new seal. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Illustration 196 g02217256 2. Replace any damaged seals with new seals. Drain the engine crankcase with the oil warm. Note: Some commercial oils that meet API specifications may require shorter oil change intervals. and repair of the product. or other portable access system) that is suitable and compliant to local regulations. Inspect the seal for the drain plug. . Remove the drain plug from the bottom of filter housings (5). If the high speed oil change is used. Illustration 198 g02217195 3. maintenance. Drain the oil into a suitable container. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. If the oil drain valve is used. man lift. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 197 g02217259 b. it may be necessary to use a portable access system (ladder. Consult your Caterpillar dealer for the latest oil recommendations. NENG2500. “Prepare the Machine for Maintenance”. Inspect the seals for the drain plugs.

176 Maintenance Section Engine Oil and Filter . Fill the crankcase with oil. Do not allow contaminants to contact the filter elements. Inspect the engine oil filters for leaks. Only use oil filters recommended by Caterpillar. install the filler cap after the oil is at the proper level. Note: Do not touch the filter elements. In order to install the filter elements. Refer to illustration 197. If the high speed oil change is used. Press each filter element upward into the housing until the element seats. Remove the oil fill hose and install the dust cover after the oil is at the proper level. crankshaft. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings. remove the filler cap (2) in order to fill with oil. b. etc. 10. a. 8. 11. NOTICE Caterpillar oil filters are built to Caterpillar specifications. Make any necessary repairs. Wash the housing cover in clean nonflammable solvent. remove the dust cover and attach the oil fill hose to male fitting (3) in order to fill with oil. Start the engine and operate the engine at an idle for 5 minutes. 7. If the filler tube is used. “Capacities (Refill)” for the amount of oil. Illustration 199 g01906696 . Install the housing covers. Refer to Operation and Maintenance Manual. Inspect the seals for the housing cover. as a result of the larger waste particles from unfiltered oil entering the engine lubricating system.. align the collapsible package to the opening of each housing. Properly discard the used filter element. “Lubricant Viscosities” for the type of oil. Remove the covers from the bottom of the filter housings. Refer to illustration 197. Remove the filter elements from the filter housings.Change SEBU8406-04 5. 9. Follow the instructions on the package of the filter element. Refer to Operation and Maintenance Manual. 6. Replace any damaged seals with new seals.

If the engine is running at low idle and the oil is at operating temperature. Prepare the machine for maintenance. “Fast Fill Service Center” for more information. 1102-535 • Cracks in the cylinder head Ensure that the engine can not be started while this maintenance is being performed. Testing and Adjusting. Refer to the Systems Operation/Testing and Adjusting Manual. Electrical shock hazard. maintain the oil level in green range (B). Refer to Operation and Maintenance Manual.SEBU8406-04 177 Maintenance Section Engine Valve Lash . Illustration 200 g01660833 2. refer to Systems Operation. 2. replace the seals. man lift. . Allow additional time for the engine to cool before measuring/adjusting valve lash clearance.Inspect SMCS Code: 1361-040 Note: In order to inspect the water pump. “Prepare the Machine for Maintenance”. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. a. Refer to Operation and Maintenance Manual. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. NOTICE Only qualified service personnel should perform this maintenance. This procedure is recommended by Caterpillar as part of a preventive maintenance schedule in order to help provide maximum engine life. KENR5397. or other portable access system) that is suitable and compliant to local regulations. “C175-16 and C175-20 Engines” or consult your Caterpillar dealer. maintain the oil level in green range (A). If the engine is stopped and the oil is cold. The overheating could result in the following problems: Engine Valve Lash Check/Adjust SMCS Code: 1102-025. Visually inspect water pump (2) for leaks. 1. b. Maintain the oil level within the green range on the sight gauge. i03578303 Engine Oil Fill with Wiggins Fast Fill Service Center (If Equipped) Refer to Operation and Maintenance Manual. stair assembly. “Valve Lash and Valve Bridge Adjustment” article or consult your Caterpillar dealer for the complete valve lash adjustment procedure.Check/Adjust 12. • Damage to the oil coolers • Piston seizure • Other potential engine damage 1. it may be necessary to use a portable access system (ladder. “Prepare the Machine for Maintenance”. For information on checking the engine valve lash. If leaks are found. To help prevent possible injury. Prepare the machine for maintenance. Hot engine components can cause burns. do not use the starting motor to turn the flywheel. i03578240 Engine Water Pump . The electronic unit injector system uses 90-120 volts. A water pump that has failed might cause severe overheating.

Refer to Operation and Maintenance Manual. 1. Personal injury may occur from failure to adhere to the following procedures. “793F Engine Supplement”. a second water pump will be installed on the engine. 4. 5. For the replacement of the water pump or the water pump seals. Do not store replacement ether cylinders in living areas or in the operator's compartment. refer to Disassembly and Assembly. Remove the used gasket for each ether starting aid cylinder and install the new gasket that is provided for each ether starting aid cylinder. 4.Replace SEBU8406-04 Note: If the machine is equipped with the additional retarding (configuration). Close the rear hood panel. If leaks are found. 2. 3. Install the new ether starting aid cylinders. Prepare the machine for maintenance. Tighten the clamps. If equipped. Do not smoke while changing ether cylinders. KENR8578. Use ether with care to avoid fires. 3. Illustration 201 g02341535 The two ether starting aid cylinders are located under the rear hood panel. Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F). i04143089 Ether Starting Aid Cylinder Replace SMCS Code: 1456-510-CD Breathing ether vapors or repeated contact of ether with skin can cause personal injury. visually inspect water pump (1) for leaks.178 Maintenance Section Ether Starting Aid Cylinder . Keep ether cylinders out of the reach of unauthorized personnel. . Open the rear hood panel. Discard cylinders in a safe place. Use ether only in well ventilated areas. Loosen the clamps (1) and unscrew the ether starting aid cylinders (2). “Prepare the Machine for Maintenance”. replace the seals. Do not puncture or burn cylinders.

• A maximum pressure of 83 bar (1200 psi) • A maximum water temperature of 50° C (120° F) • Hold the nozzle perpendicular to the product identification film at a minimum distance of 305 mm (12 inch). stair assembly. Hand Washing Use a wet solution with no abrasive material that contains no solvents and no alcohol. or a sponge in order to clean the product identification films. it may be necessary to use a portable access system (ladder. allowing the product identification film to lift or curl. Clean the product identification films or replace the films. 7557-070 Illustration 202 g02174985 • Use a spray nozzle with a wide spray pattern. g02175297 SMCS Code: 7050-571 Note: The graphics that are shown are for illustrative purposes. Make sure that the recommended procedures are used in order to clean the product identification films. However.Clean/Inspect Illustration 203 Typical example of the Product Identification Films. Note: In order to access areas of the frame. aggressive washing can damage the product identification films. Ensure that all the product identification films are not damaged or missing. follow these important steps: Film (Product Identification) Clean SMCS Code: 7405-070. attach the body (bed) retaining cables to the rear tow points. • Do not direct a stream of water at a sharp angle to i04340076 Frame . Failure to properly secure the body (bed) may result in personal injury or death. man lift. the edge of the product identification film. Ensure that the surface of the product identification films is flushed with clean water and allow the product identification films to air dry. . Cleaning of the Films Make sure that all of the product identification films are legible. Use a soft brush. These problems are magnified by wind. This procedure is an in-chassis inspection. Use a wet solution with a “pH” value between 3 and 11. a rag. or other portable access system) that is suitable and compliant to local regulations. These problems are critical for the perforated film on windows.SEBU8406-04 179 Maintenance Section Film (Product Identification) . Avoid wearing down the surface of the product identification films with unnecessary scrubbing.Clean i03997106 Power Washing Power washing or washing with pressure may be used in order to clean product identification films. Install the rear tow point pins through the ends of the retaining cables. To avoid lifting of the edge or other damage to the product identification films. Excessive pressure during power washing can damage the product identification films by forcing water underneath the product identification films. Water lessens the adhesion of the product identification film to the product. When it is necessary to work under the machine with the body (bed) raised.

180 Maintenance Section Frame and Body - Inspect

SEBU8406-04

Note: In order to access the body and areas of the frame, it may be necessary to use a portable access system (ladder, stair assembly, man lift, or other portable access system) that is suitable and compliant to local regulations. 1. Secure the dump body in the fully raised position and prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Illustration 204

g01907234

1. Secure the dump body in the fully raised position and prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”. 2. Clean the frame with a high-pressure washer. 3. Inspect the frame for damage and for cracks. If you find cracks or damage, consult your Cat dealer for specific repair procedures. Do not operate the machine until the necessary repairs have been made.
i04340049

Illustration 205

g01907375

2. Clean the frame and the body. Inspect the dump body. If the frame is damaged or worn, consult your Cat dealer for repair procedures. 3. Clean the dump body with a wire brush or a scraper. Inspect the dump body. If the dump body is damaged or worn, consult your Cat dealer for repair procedures.
i04339997

Frame and Body - Inspect
SMCS Code: 7050-040; 7258-040 Note: The graphics that are shown are for illustrative purposes. This procedure is an in-chassis inspection.

Frame and Body Support Pads - Clean/Inspect
SMCS Code: 7050-571; 7258-571-S4 Note: The graphics that are shown are for illustrative purposes. This procedure is an in-chassis inspection.

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the rear tow points. Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death.

SEBU8406-04

181 Maintenance Section Front Wheel Oil - Change

i03579481

When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cables to the rear tow points. Install the rear tow point pins through the ends of the retaining cables. Failure to properly secure the body (bed) may result in personal injury or death. Note: In order to access the body support pads and areas of the frame, it may be necessary to use a portable access system (ladder, stair assembly, man lift, or other portable access system) that is suitable and compliant to local regulations. 1. Secure the dump body in the fully raised position and prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

Front Wheel Oil - Change
SMCS Code: 4201-044-OC Note: The oil change interval for the front wheel bearing can be monitored with the S·O·S scheduled oil sampling program. The interval is based on the condition of the oil. If the S·O·S scheduled oil sampling program is not used, the oil change for the front wheel bearing should be performed at 500 service hours or 3 months.

Illustration 207

g01579113

1. Position the front wheel so that drain plug (1) is facing downward. 2. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.
Illustration 206
g01907478

2. Clean the body support pads. 3. Remove the truck body retaining cables and lower the dump body. For the proper procedure, refer to Operations and Maintenance Manual, “Cable (Truck Body Retaining)”. 4. Visually inspect each of the body support pads. Look for damage or uneven wear of the body support pads. Look for gaps between the body support pads and the mating surfaces. If problems are found, consult your Cat dealer for more information or for specific repair procedures.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 3. Remove the drain plug.

182 Maintenance Section Front Wheel Oil - Inspect

SEBU8406-04

4. Inspect the magnetic drain plug. If any abnormal particles are found, consult your Caterpillar dealer. 5. Allow the oil to drain into a suitable container. 6. Clean the drain plug and install the drain plug. 7. Remove the filler plug (2). 8. Fill the oil compartment to the bottom of the opening for the filler plug. Refer to Operation and Maintenance Manual, “Lubricant Viscosities”. Refer to Operation and Maintenance Manual, “Capacities (Refill)”. 9. Clean the filler plug and install the filler plug. Use the same procedure for the other front wheel.
i03657364

Front Wheel Oil - Inspect
SMCS Code: 4201-040-OC 1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”. 2. Inspect the oil from the front wheel for any of the following symptoms that may indicate a mechanical failure:

Illustration 208

g01578653

2. Use sight gauges (1) in order to check the oil level in each front wheel. 3. Maintain the oil level to the bottom of filler plug (2). a. If the oil level is excessive, inspect the oil for water contamination. 4. If necessary, remove the filler plug and add oil. a. if the oil level is low, inspect the area around the wheel spindle for leaks and inspect the magnetic plug.
i03657373

• Discoloration and change in viscosity • A high amount of metal on the magnetic plug • Oil leaks in the area around the front wheel
spindle

• Review the latest results and trends from the
S·O·S samples The front wheel bearings do not need to be adjusted or inspected until the scheduled overhaul. Unless a symptom of an obvious failure appears, do not adjust or inspect the front wheel bearings. If the oil from the front wheel has any of the above symptoms, the front wheel bearings may need to be inspected. Consult your Caterpillar dealer for more information.
i03579820

Front Wheel Oil Sample Obtain
SMCS Code: 4201-008-OC; 7542

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.

Front Wheel Oil Level - Check
SMCS Code: 4201-535-FLV 1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

“S·O·S Services Analysis” Good S·O·S Sample” • Special Publication.Fill (Fast Fill Fuel Adapter) SMCS Code: 1250-544 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. you must establish a consistent trend of data. 1. SEBU6250. “Capacities (Refill)” for available fuel tank capacities. 3. Supplies for collecting samples can be obtained from your Caterpillar dealer. “Caterpillar Machine Fluids Recommendations”. and repair of the machine. NOTICE Use only a Caterpillar approved fast fill system to fuel machines. “S·O·S Services: Understanding Your Results” Analysis” Illustration 210 g01908435 • Special Publication. “S·O·S Information” • Special Publication. Remove filler plug (1) for the front wheel and obtain an oil sample through the filler plug opening. PEGJ0046. Contact your Cat dealer for fast fill system availability. maintenance. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. perform consistent samplings that are evenly spaced. adjusting. i03579860 Fuel System . . Remove dust cover (1) and clean the fast fill fuel adapter. Over pressurization may cause tank deformation and fuel spillage. 1. “Prepare the Machine for Maintenance”. Refer to the following publications for S·O·S information: • Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. Clean the fuel nozzle adapter on the bulk fuel supply. Refer to Operation and Maintenance Manual. In order to establish a pertinent history of data.Fill Obtain S·O·S samples as close as possible to the recommended sampling interval. Submit the sample for S·O·S analysis. testing. Dispose of all fluids according to local regulations and mandates. Refer to Operation and Maintenance Manual. Illustration 209 g01962287 2. PEGJ0047. Prepare the machine for maintenance. “S·O·S Fluid 2. In order to receive the full effect of S·O·S analysis. “How to Take a • Special Publication. PEHJ0191. “Prepare the Machine for Maintenance”.SEBU8406-04 183 Maintenance Section Fuel System . Prepare the machine for maintenance. 3.

consult your Caterpillar dealer. Observe the fuel gauge in order to prevent overfilling. 4.184 Maintenance Section Fuel System . Move the engine start switch to the ON position. Illustration 212 g01943185 4. Do not operate the priming pump for more than three minutes. . Illustration 211 g01942894 9. Connect a hose to quick connect port (1). 6. The priming pump will fill the engine fuel lines and the fuel filters with fuel. An ultrasonic level indicator is located in the fuel tank in order to send data to a fuel gauge on the filler. The trapped air is purged through the hose that is attached to the quick connect port. release the switch.Prime SEBU8406-04 Note: The maximum fuel flow rate for the fast fill fuel adapter group is 375 L/min (100 US gpm). Refer to Operation and Maintenance Manual. If the engine does not start after several attempts. Immediately clean up any spilled fuel. 7. i03579887 Fuel System . If the engine starts but the engine runs rough. 8. Start the engine. Hold switch (2) upward in order to activate the electric fuel priming pump. continue to run the engine at an idle until the engine runs smoothly. Place the other end of the hose into a suitable container in order to collect fuel that is purged from the fuel system. the fuel will become a steady stream that is free of air. Observe the Advisor display for messages. Fill the fuel tank through the fast fill fuel adapter. Prepare the machine for maintenance. Install the dust cover on the adapter. Clean up fuel spills immediately. 2. 5. 3. As the air is purged. 1. When the fuel becomes a steady stream. 5. Extended engine cranking may be required in order for the high pressure fuel lines to build adequate fuel pressure. Clean the fast fill fuel adapter and the dust cover.Prime SMCS Code: 1250-548 Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Disconnect the hose from the quick connect port. “Prepare the Machine for Maintenance”. 6.

testing. Refer to Operation and Maintenance Manual. Dispose of all fluids according to local regulations and mandates. Prepare the machine for maintenance. maintenance.SEBU8406-04 185 Maintenance Section Fuel System Primary Filter (Water Separator) . Contaminated fuel will cause accelerated wear to fuel system parts. i03580206 Fuel System Primary Filter (Water Separator) . Close the drain valves when all of the water has been drained. NOTICE Do not fill fuel filters with fuel before installing them. 1263-543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Prepare the machine for maintenance. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. NENG2500. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Illustration 213 g01908538 The primary fuel filters (water separator) are located behind the fuel tank. 2. “Prepare the Machine for Maintenance”.Replace SMCS Code: 1261-510. adjusting and repair of the product. testing. maintenance. adjusting and repair of the product. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.Drain i03579911 Fuel System Primary Filter (Water Separator) . Clean up fuel spills immediately. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Personal injury or death can result if spilled fuel ignites. . The fuel will not be filtered and could be contaminated. The fuel tank has been removed for ease of viewing. Refer to Special Publication. turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. The fuel system should be primed prior to starting the engine. 1. Refer to Special Publication. Open drain valves (1) on the bottom of both fuel/water separator elements in order to drain the water into a suitable container. 1263-510 Replace the fuel/water separator elements when the engine has a loss of power or when the exhaust smoke is black. 1. “Prepare the Machine for Maintenance”. To help prevent possible injury. Refer to Operation and Maintenance Manual.Drain SMCS Code: 1261-543. NENG2500. 3. Dispose of all fluids according to local regulations and mandates.

Prime the fuel system. 8. Drain fuel/water separator elements (2) into a suitable container. The fuel system should be primed prior to starting the engine. Note: You may need to use a strap type wrench or a suitable tool in order to turn the filters to the amount that is required for final installation. Lubricate the seals of the new elements with clean diesel fuel. Start the engine and inspect the filter for leaks. Note the position of the index marks on the elements in relation to a fixed point on the mounting base. Make sure that both of the old seals are removed. To help prevent possible injury. Close fuel shutoff valve (1). testing. refer to the Operation and Maintenance Manual. The fuel will not be filtered and could be contaminated. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Refer to Special Publication. Remove the fuel/water separator elements. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Make sure that the installation tool does not damage the filters. Dispose of all fluids according to local regulations and mandates. replace the secondary filters. Prepare the machine for maintenance. turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements. adjusting and repair of the product. 1. use the rotation index marks as a guide.Replace SEBU8406-04 For information on priming the fuel system. 2. . 10. Clean up fuel spills immediately. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. “Prepare the Machine for Maintenance”. Make any necessary repairs. Open the fuel shutoff valve. If the engine has a loss of power or the exhaust smoke is still black. Clean the mounting base. Contaminated fuel will cause accelerated wear to fuel system parts. “Fuel System . 5. Tighten all filters according to the instructions that are printed on the filter. Properly discard the used elements. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. 6. i03580266 Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE Illustration 214 View of the back side of the fuel tank g01908734 Personal injury or death can result if spilled fuel ignites. 9.186 Maintenance Section Fuel System Secondary Filter . 3.Prime”. maintenance. Refer to Operation and Maintenance Manual. Install the new elements by hand until the seal contacts the mounting base. 4. NOTICE Do not fill fuel filters with fuel before installing them. NENG2500. 7. 11. When you tighten the elements.

Refer to Special Publication. Install the new elements by hand until the seal contacts the mounting base. testing.Drain 5. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. . 9. Open the fuel shutoff valve. NENG2500. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. Remove the filter elements from the base. Make sure that the installation tool does not damage the filters. 1. refer to the Operation and Maintenance Manual. 10. Prime the fuel system. “Fuel System . Note: You may need to use a strap type wrench or a suitable tool in order to turn the filters to the amount that is required for final installation. Clean the filter mounting bases. Close fuel shutoff valve (1). i03580480 2. 6. 7. Fuel Tank Water and Sediment . use the rotation index marks as a guide. Tighten all filters according to the instructions that are printed on the filter. “Prepare the Machine for Maintenance”. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Discard the used elements. Illustration 216 g01908875 Dispose of all fluids according to local regulations and mandates. Refer to Operation and Maintenance Manual.SEBU8406-04 187 Maintenance Section Fuel Tank Water and Sediment .Drain SMCS Code: 1273-543-MAS NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Prepare the machine for maintenance. Illustration 215 View of the back side of the fuel tank g01908877 8. adjusting and repair of the product. 3. When you tighten the elements. For information on priming the fuel system. Start the engine and inspect the filter for leaks. 4. Make any necessary repairs.Prime”. Make sure that all of the former seals are removed. Lubricate the seals of the new elements with clean diesel fuel. Secondary fuel filters (2) are located on the right side of the engine. maintenance. Note the position of the index marks on the elements in relation to a fixed point on the mounting base.

Replace/Reset SEBU8406-04 Illustration 217 View of the back side of the fuel tank g01167012 2. 3. Circuit Breakers and Relays .Replace/Reset SMCS Code: 1417-510. 1422-510 Illustration 218 g01962341 Location of the electrical panel or the fuses. the circuit breakers. i03593377 Fuses. and the relays The electrical panel for the fuses. and the relays is positioned behind the seat on the right rear of the operator station. the circuit breakers. . 1420-510.188 Maintenance Section Fuses. Open fuel tank drain valve (1) and allow the moisture and the sediment to drain into a suitable container. Circuit Breakers and Relays . Close the drain valve.

Repair the electrical circuit. an electrical problem may exist. Use the tool that is stored on the electrical panel in order to remove the fuses. Contact your Caterpillar dealer. If the fuse of a particular electrical system requires frequent replacement. Circuit Breakers and Relays . Replace a fuse if the element separates. electrical damage could result. Fuses protect the electrical system from damage that is caused by overloaded electrical circuits. check the electrical circuit.Replace/Reset Fuses Illustration 219 g01919410 NOTICE If it is necessary to replace fuses frequently. NOTICE Always replace fuses with the same type and capacity fuse that was removed.SEBU8406-04 189 Maintenance Section Fuses. if necessary. 12 Volt Fuses Spare Fuse (A) – 12 V with connector . Otherwise.

190 Maintenance Section Fuses.Replace/Reset SEBU8406-04 Radio (1) – 20 Amp Work Lights (13) – 15 Amp MineStar (2) – 15 Amp Heated Mirror (14) – 20 Amp (Right mirror and front mirror) 12 Volt Power Port (3) – 15 Amp (Dash panel) 12 Volt Power Port (4) – 15 Amp (Rear panel) Communication Radio (5) – 20 Amp (Prewired harness in the headliner) Air Seat (15) – 20 Amp (Passenger) Cab Air Cleaner (16) – 20 Amp Heated Mirror (17) – 20 Amp (Left mirror) Cigar Lighter (6) – 15 Amp Autolube System (18) – 20 Amp CB Radio (7) – 15 Amp (Prewired Harness in the rear panel) Chassis Power (19) – 10 Amp Entertainment Radio (Memory) (8) – 15 Amp Fog Lights (20) – 20 Amp 24 Volt Fuses Spare Fuse (B) – 24 V with connector Electronic Engine Thermostat (21) – 15 Amp Camera Lights (22) – 20 Amp Window Washer and Wiper (9) – 20 Amp WAVS (23) – 15 Amp Air Dryer (10) – 15 Amp VIMS 3G (24) – 15 Amp Air Start System (11) – 20 Amp Product Link (25) – 15 Amp Air Seat (12) – 20 Amp (Operator) Brake ECM (26) – 20 Amp . Circuit Breakers and Relays .

Advisor Display.Replace/Reset Engine ECM (27) – 20 Amp Keyswitch (28) – 10 Amp HVAC Water Valve (29) – 20 Amp Stairway Access Lights (30) – 20 Amp Horn (31) – 10 Amp Chassis ECM (32) – 20 Amp 24 Volt to 12 Volt Converter (33) – 20 Amp Drive Train ECM (34) – 20 Amp Gauge Cluster.SEBU8406-04 191 Maintenance Section Fuses. Retarder Lever Sensor (35) – 10 Amp Interior Service Tool Port (36) – 15 Amp . Circuit Breakers and Relays .

Circuit Breakers and Relays . and the fog lights are automatic reset circuit breakers. check the appropriate electrical circuit. the high beam headlights. Use the tool that is stored on the electrical panel in order to remove the circuit breakers.Replace/Reset SEBU8406-04 Circuit Breakers Illustration 220 g01919409 Push in the button in order to reset the circuit breaker. If the electrical system is working properly. if necessary. If the button does not remain depressed. Spare Circuit Breaker (C) – 24 V with connector Brake Retraction Motor (37) – 20 Amp High Speed Blower (38) – 20 Amp Headlights (39) – 15 amp Air Conditioner Compressor (40) – 20 Amp . the button will remain depressed. Repair the electrical circuit. Note: The circuit breakers for the low beam headlights.192 Maintenance Section Fuses.

Replace/Reset Power Window (Left) (41) – 20 Amp Power Window (Right) (42) – 20 Amp Fuel Priming Pump / Fuel Control Valve (43) – 15 Amp Relays Illustration 221 g01919407 . Circuit Breakers and Relays .SEBU8406-04 193 Maintenance Section Fuses.

Use the tool that is stored on the electrical panel in order to remove the relays. To avoid electrical shock and personal injury.194 Maintenance Section High Intensity Discharge Lamp (HID) .Replace (If Equipped) SMCS Code: 1434-510 Window Wiper (54) – Slow/Intermittent Window Wiper (55) – High HID lamps operate at very high voltages.Replace SEBU8406-04 A relay is an electrical switch that opens and closes under the control of another electrical circuit. . Spare Relay (D) – 24 V with connector Window Washer (56) Cab Air Cleaner (57) Drive Train Lamp (44) Fuel Priming Pump / Fuel Control Valve (58) Stop Lamp (45) Engine Prelube (59) Headlight (46) VIMS Blue Lamp (60) – Service Light Autolube (47) Rear Window Wiper (61) Idle Shutdown Timer (48) Engine Lockout Lamp (62) VIMS Green Lamp (49) – Payload Front Camera (63) – WAVS VIMS Red Lamp (50) – Payload Air Conditioner Clutch (64) Horn (51) Backup Alarm (65) Rear Camera Lights (52) i02245859 Engine Lockout (53) High Intensity Discharge Lamp (HID) . disconnect power before servicing HID lamps.

1. NENG2500. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on the machine. Clean the screens whenever there is a failure of the brakes. Replace the entire lens assembly on these HID lamps.Clean i04339971 HID bulbs become very hot during operation. or hoist pumps. Hot oil and hot components can cause personal injury. If the bulb is an integral part of the lens assembly. install the replacement lens assembly in the HID lamp. maintenance. Check the HID lamp for proper operation. adjusting. 5. Do not allow hot oil or hot components to contact the skin. please use caution and comply with any applicable laws. 1. the bulb is an integral part of the lens assembly. 4. When disposing of this component. hoist cylinders. attach the body (bed) retaining cables to the rear tow points. 2. Remove the bulb from the HID lamp. Install the replacement bulb in the HID lamp. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 2. Note: Consult your Caterpillar dealer for additional information on HID lamps. 3. Failure to properly secure the body (bed) may result in personal injury or death. Reattach the electrical power to the HID lamp. . Dispose of all fluids according to local regulations and mandates. Remove the electrical power from the high intensity discharge lamp (HID). Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Disassemble the housing for the HID lamp in order to have access to the bulb. Clean any fingerprints from the bulb with alcohol prior to operation. NOTICE Although HID bulb materials may change over time. or any waste that contains mercury. Before servicing. HID bulbs produced at the time of the printing of this manual contain mercury. “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat products. in order to ensure that the bulb is cool. Refer to Special Publication. testing. Use the Advisor display in order to verify that the hoist/brake system is relieved of any hydraulic pressure. remove power from lamp for at least five minutes to ensure lamp is cool. Install the rear tow point pins through the ends of the retaining cables. Secure the dump body in the fully raised position and prepare the machine for maintenance. 6. 7. avoid touching the bulb's surface with your bare hands. Note: On some HID lamps. Hoist Screens . and repair of the product. Note: In order to avoid failure to the bulb that is premature.Clean SMCS Code: 5057-070-Z3 When it is necessary to work under the machine with the body (bed) raised. “Prepare the Machine for Maintenance”.SEBU8406-04 195 Maintenance Section Hoist Screens . Refer to Operation and Maintenance Manual. The bulb is not removed separately from the lens assembly. The electrical power must be removed from the HID lamp for at least five minutes. Reassemble the housing for the HID lamp.

5. Install the clean hoist screens and the hoses. Inspect all clamps for the following conditions: 3. Always use a board or cardboard when the engine components are checked for leaks.Inspect/Replace SEBU8406-04 i03855189 Hoses and Clamps Inspect/Replace SMCS Code: 1000. Replace the seals during installation. oil hose.196 Maintenance Section Hoses and Clamps . Remove the hoist screens from the housings. refer to Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. Remove the truck body retaining cables and lower the body. Drain the oil from the lines into a suitable container. • Outer covering that is ballooning locally • Flexible part of the hose that is kinked or crushed • Armoring that is embedded in the outer covering • Hoses which exhibit signs of leakage which are not the result of loose couplings or clamps Replace any hoses that exhibit any of the above conditions. 4. Clean the hoist screens in clean nonflammable solvent. fuel hose. Start the engine and operate the engine at an idle. Remove hoses (1) from screen housings (2). Check for leaks and make any necessary repairs. Leaking fluid that is under pressure can cause serious injury or possible death. add oil. 8. 7554-040.Check”. “Hoist and Brake Tank Oil Level . . For the proper procedure. 6. Inspecting Hoses and Clamps Inspect all hoses for the following conditions: • Hoses which are cracked • Hoses which are soft • Outer covering that is chafed or cut • Exposed wire that is used for reinforcement Illustration 222 g01909133 The machine is shown without the dump body for ease of viewing. 7554-510 Hoses and clamps for the engine must be inspected periodically in order to ensure safe operation and continuous operation of the engine. 7. Note: Take proper safety precautions before inspecting or replacing hoses and clamps. If necessary. and air hose (compressed air or intake air). A hose for the engine may include the following: coolant hose. Inspect all couplings for leaks. “General Hazard Information” for more information. Replace any coupling which exhibits signs of leaks. Check the oil level in the hoist/brake tank. • Cracking • Looseness • Damage Replace any clamps that exhibit any of the above conditions.

SENR3130. drain the coolant to a level that is below the hose. Replacing Hoses and Clamps At operating temperature. Do not allow hot coolant or hot components to contact the skin. Fill the affected system to the proper fluid level. Prepare the machine for maintenance and allow the engine to cool. Note: Refer to Specifications. 2. 1. Failure to relieve pressure can cause personal injury. “Caterpillar Dealer Service Tool Catalog” or refer to Special Publication. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. .Replace Each installation application can be different. Check for leaks and make necessary repairs. 5. “Torque Specifications”. Dispose of all fluids according to local regulations and mandates. Heat setting causes hose clamps to loosen. Replace any damaged clamps. Replace any damaged hoses.Replace (Brake Pump Charge Filter) SMCS Code: 5068-510 Hot oil and hot components can cause personal injury. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.SEBU8406-04 197 Maintenance Section Hydraulic Oil Filter . 4. Drain the coolant into a suitable clean container. This can result in leaks. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. engine coolant is hot and under pressure. 3. adjusting and repair of the product. i03583361 Hydraulic Oil Filter . the hose will heat set. The differences depend on the following factors: • Type of hose • Type of fitting material • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings Due to extreme temperature changes. “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Do not allow hot oil or hot components to contact the skin. Do not allow hot oil or hot components to contact the skin. Refer to Special Publication. NENG2500. If a coolant hose needs to be replaced. testing. PECJ0003. Start the engine and operate the engine at low idle. Personal injury can result from removing hoses or fittings in a pressure system. Hot oil and hot components can cause personal injury. A constant torque hose clamp will help to prevent loose hose clamps. The coolant can be reused. “Hose Clamps” for information about selecting and installing the proper hose clamps. maintenance. Hot coolant and hot components can cause severe burns.

Replace a damaged seal with a new seal. Refer to Special Publication. Remove drain plug (1) from end cap (2). If necessary. 9. Inspect the oil filter for leaks. Remove the end cap from the filter housing. i03583701 Hydraulic Oil Filter . Refer to Operation and Maintenance Manual. 7. Note: The hoist system and the brake system share common oil. Install the end cap on the filter housing. Wash the end cap in clean nonflammable solvent. Prepare the machine for maintenance. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Install the new filter element. Make any necessary repairs. Note: The hoist system and the brake system share common oil. Refer to Operation and Maintenance Manual.198 Maintenance Section Hydraulic Oil Filter . Start the engine and operate the engine at an idle for five minutes. Prepare the machine for maintenance. Remove the filter element. “Hydraulic Tank Oil Level . Do not allow hot oil or hot components to contact skin.Check (Hoist and Brake System)”. For the proper procedure. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 8. “Prepare the Machine for Maintenance”. Illustration 223 g01911833 2. add oil. maintenance. NENG2500. Check the oil level in the hoist/brake tank. Dispose of all fluids according to local regulations and mandates. adjusting and repair of the product. refer to Operation and Maintenance Manual. Refer to Special Publication. Properly discard the used filter element. Drain the oil into a suitable container. Inspect the seal for the drain plug. adjusting and repair of the product. 1. testing.Replace SEBU8406-04 4. 1. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 6. maintenance. . 5. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Inspect the seal for the end cap. Replace a damaged seal with a new seal. NENG2500.Replace (Brake Cooling Filter) SMCS Code: 5068-510 Hot oil and hot components can cause personal injury. Dispose of all fluids according to local regulations and mandates. 3. “Prepare the Machine for Maintenance”. Wash the drain plug in clean nonflammable solvent and install the drain plug. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.

Dispose of all fluids according to local regulations and mandates. If necessary. Wash the end cap in clean nonflammable solvent. For the proper procedure. 1. Refer to Special Publication. 6. Make any necessary repairs. Do not allow hot oil or hot components to contact the skin. and repair of the product. Remove the filter element. Wash the drain plug in clean nonflammable solvent and install the drain plug. refer to Operation and Maintenance Manual.SEBU8406-04 199 Maintenance Section Hydraulic Oil Filter . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Drain the oil into a suitable container. 3. add oil. Inspect the seal for the drain plug. . Replace a damaged seal with a new seal. maintenance. Properly discard the used filter element. Replace a damaged seal with a new seal. Note: The steering system and the hydraulic fan drive motor for the engine share common hydraulic oil.Replace (Steering and Fan System Oil Return) SMCS Code: 5068-510 Hot oil and hot components can cause personal injury. Remove drain plug (1) from end cap (2). 8. 4. Install the end cap on the filter housing. 9. “Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Cat products.Check (Hoist and Brake System)”. Install the new filter element. testing. “Hydraulic Tank Oil Level . Start the engine and operate the engine at an idle for five minutes. Refer to Operation and Maintenance Manual. adjusting. Remove the end cap from the filter housing. Illustration 224 g01912053 2.Replace i04030021 Hydraulic Oil Filter . Check the oil level in the hoist/brake tank. Prepare the machine for maintenance. Inspect the oil filter for leaks. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. “Prepare the Machine for Maintenance”. NENG2500. Inspect the seal for the end cap. 5. 7.

In order to prevent a vacuum. vent the oil filter housing by placing an individual fitting on sampling port (1). . 4. a vacuum can create a siphon effect and drain the oil from the steering tank.200 Maintenance Section Hydraulic Oil Filter . Check the oil level in the steering system. Remove the filter element. Install the new filter element. Remove drain plug (2) from end cap (3). Wash the drain plug with clean nonflammable solvent and install the drain plug.Check (Steering System)”.Replace SEBU8406-04 Illustration 226 g02217453 3. Inspect the seal for the drain plug. 8. 10. add oil. Illustration 225 g01912513 2. 9. refer to Operation and Maintenance Manual. Remove the end cap from the filter housing. If necessary. Wash the end cap in clean nonflammable solvent. For the proper procedure. 6. 5. When draining the oil filter housing. Drain the oil into a suitable container. Replace a damaged seal with a new seal. Make any necessary repairs. Replace a damaged seal with a new seal. Inspect the seal for the end cap. “Hydraulic Tank Oil Level . Inspect the oil filter for leaks. Properly discard the used filter element. Start the engine and operate the engine at an idle for 5 minutes. Install the end cap on the filter housing. 7.

Wash the drain plug in clean nonflammable solvent and install the drain plug. Remove the filter element. 1. Do not allow hot oil or hot components to contact the skin. “Prepare the Machine for Maintenance”. 5. For the proper procedure. Remove the filter housing. 7. 6. 4.Replace i03583580 Hydraulic Oil Filter . If necessary. 8. Check the oil level in the steering system. add oil. Drain the oil into a suitable container. Inspect the oil filter for leaks. Refer to Operation and Maintenance Manual. NENG2500. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Remove the drain plug from the bottom of filter housing (1). Refer to Special Publication. . NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.SEBU8406-04 201 Maintenance Section Hydraulic Oil Filter . Make any necessary repairs.Replace (Hydraulic Pump Case Drain Steering and Fan System) SMCS Code: 5068-510 Hot oil and hot components can cause personal injury. “Hydraulic Tank Oil Level .Check (Steering System)”. 3. Wash the filter housing in clean nonflammable solvent. Prepare the machine for maintenance. Inspect the seal for the filter housing. Install the filter housing. testing. Start the engine and operate the engine at an idle for five minutes. Note: The steering system and the hydraulic fan drive motor for the engine share common hydraulic oil. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. maintenance. Properly discard the used filter element. Install the new filter element. 9. 2. Replace a damaged seal with a new seal. adjusting and repair of the product. Inspect the seal for the drain plug. Replace a damaged seal with a new seal. refer to Operation and Maintenance Manual. Illustration 227 g01911953 Dispose of all fluids according to local regulations and mandates.

In order to establish a pertinent history of data. In order to receive the full effect of S·O·S analysis. Obtain S·O·S samples as close as possible to the recommended sampling interval. “Prepare the Machine for Maintenance”. Do not allow hot oil or hot components to contact the skin. you must establish a consistent trend of data. 1. Illustration 228 g01912555 2. you must establish a consistent trend of data. Prepare the machine for maintenance. 1. PEGJ0047. “How to Take a • Special Publication.Obtain SEBU8406-04 i03584102 3. Prepare the machine for maintenance. “S·O·S Services Analysis” Good S·O·S Sample” Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Submit the sample for S·O·S analysis. “Caterpillar Machine Fluids Recommendations”. . Supplies for collecting samples can be obtained from your Caterpillar dealer. “Prepare the Machine for Maintenance”. “S·O·S Fluid i03584080 Hydraulic System Oil Sample . perform consistent samplings that are evenly spaced. SEBU6250.Obtain (Hoist and Brake System) SMCS Code: 5050-008-OC. Refer to the following publications for S·O·S information: Hydraulic System Oil Sample . 7542 Hot oil and hot components can cause personal injury. Supplies for collecting samples can be obtained from your Caterpillar dealer. Refer to Operation and Maintenance Manual.Obtain (Steering System) SMCS Code: 5050-008-OC. Note: The steering system and the hydraulic fan drive motor for the engine share common hydraulic oil. In order to establish a pertinent history of data. “S·O·S Services: Understanding Your Results” Analysis” • Special Publication. PEGJ0046. 7542 • Operation and Maintenance Manual. • Special Publication. Obtain S·O·S samples as close as possible to the recommended sampling interval. PEHJ0191.202 Maintenance Section Hydraulic System Oil Sample . Take the oil sample when the engine is operating at low idle. In order to receive the full effect of S·O·S analysis. Obtain a sample of the hoist and brake oil through sampling valve (1). perform consistent samplings that are evenly spaced. “S·O·S Information” • Special Publication. Refer to Operation and Maintenance Manual.

Prepare the machine for maintenance. Refer to the following publications for S·O·S information: • Operation and Maintenance Manual. testing. Take the oil sample when the engine is operating at low idle. PEGJ0046. Refer to Operation and Maintenance Manual. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. man lift. 1.Change i03584162 Hydraulic Tank Oil . Note: In order to access the filler cap. Refer to Special Publication. maintenance. and the sight gauges. 3. Do not allow hot oil or hot components to contact the skin. Remove filler cap (1) in order to prevent a vacuum in the tank. PEHJ0191. the drain valve. “S·O·S Services Analysis” Good S·O·S Sample” • Special Publication. “Prepare the Machine for Maintenance”. Illustration 229 g01912513 2. the filler strainer. “Caterpillar Machine Fluids Recommendations”. NENG2500. stair assembly. “How to Take a • Special Publication.Change (Hoist and Brake System) SMCS Code: 5056-044-OC Hot oil and hot components can cause personal injury. “S·O·S Information” • Special Publication. “S·O·S Services: Understanding Your Results” Analysis” Illustration 230 g01912584 • Special Publication.SEBU8406-04 203 Maintenance Section Hydraulic Tank Oil . NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. . or other portable access system) that is suitable and compliant to local regulations. SEBU6250. Submit the sample for S·O·S analysis. adjusting and repair of the product. “S·O·S Fluid 2. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Obtain a sample of the steering system oil through sampling valve (1). it may be necessary to use a portable access system (ladder. Dispose of all fluids according to local regulations and mandates. PEGJ0047.

12. Install a 88. Open drain valve (2). Drain the oil into a suitable container. if necessary. Add oil to the tank in order to raise the oil within the green range of the upper sight gauge.Change SEBU8406-04 Illustration 232 g01912579 The engine shutdown switch is located above the right side of the front bumper. Allow the cap and the strainer to dry. the brake reservoir will fill first. Raise the truck body until the hoist cylinders are extended halfway. Lower the truck body and add oil.204 Maintenance Section Hydraulic Tank Oil . “Capacities (Refill)”. 5. Drain the oil into a suitable container.Check (Hoist and Brake Oil)” for more information. Refer to Operation And Maintenance Manual. Remove the filler strainer. Close the drain valve. 7. . When the hoist/brake tank is filled. 4. Inspect the cap seal. 3. 10. 9.0 mm (3. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). Install the strainer. Remove drain valve plug (3). 8. Start the engine and operate the engine at an idle. 6. Crank the engine for approximately 15 seconds. Wash the cap and the strainer in clean. if necessary. Lower the truck body and add oil. the oil will flow into the hoist reservoir. Refer to Operation and Maintenance Manual. g01912581 Illustration 231 11. Refer to Operation And Maintenance Manual. Clean the drain plug and install the drain plug. Fill the hoist/brake tank within green range (A) of upper sight gauge (5). Use engine shutdown switch (4) to prevent the engine from starting. Use a new seal if the used seal is damaged. Remove the pipe nipple. Repeat Step 9 and Step 10 until the oil level stabilizes within the green range of the upper sight gauge. Note: The hoist reservoir and the brake reservoir are separated by a baffle. The oil level will decrease as oil fills the system. 14.50 inch) long NPT pipe nipple in order to open the internal drain valve. “Hydraulic Tank Oil Level . After the brake reservoir is at the proper level. Raise the truck body until the hoist cylinders are fully extended. nonflammable solvent. Lower the guard on the engine shutdown switch. 13. “Lubricant Viscosities”.

1. “Prepare the Machine for Maintenance”.Change (Steering System) SMCS Code: 5056-044-OC Hot oil and hot components can cause personal injury. “Hydraulic Tank Oil Level . 17. man lift. Illustration 233 g01912580 15. Dispose of all fluids according to local regulations and mandates. the filler strainer. adjusting and repair of the product.SEBU8406-04 205 Maintenance Section Hydraulic Tank Oil . Do not allow hot oil or hot components to contact the skin. Prepare the machine for maintenance. or other portable access system) that is suitable and compliant to local regulations. i03585044 Note: In order to access the filler cap. Illustration 234 g01913417 .Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Inspect the hoist/brake tank for leaks and make any necessary repairs. the filler tube. Repeat Step 13 and Step 14 until the oil level stabilizes within the green range of the upper sight gauge. 16. Note: The steering system and the hydraulic fan drive motor for the engine share common hydraulic oil. it may be necessary to use a portable access system (ladder. Refer to Operation and Maintenance Manual. Check oil level in the hoist/brake tank. Refer to Special Publication. stair assembly. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Hydraulic Tank Oil . and the sight gauges. NENG2500.Check (Hoist and Brake System)”. maintenance. Refer to Operation and Maintenance Manual.

Use the reading from upper sight gauge (2) to maintain the steering oil level.Check SEBU8406-04 2. The oil level in the upper sight gauge should be within green range (A) with the engine stopped.206 Maintenance Section Hydraulic Tank Oil Level . 2. Check for leaks and make any necessary repairs. 3. Start the engine and operate the engine at an idle for five minutes. Install the strainer. remove filler cap (1) and add oil. 3. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). See Operation And Maintenance Manual. For information on the oil level for the steering system. Inspect the cap seal. Fill the steering hydraulic tank within the green range of upper sight gauge (2). If necessary. Install the filler cap. Wash the cap and the strainer in clean. 8.0 mm (3. Use a new seal if the used seal is damaged. “Lubricant Viscosities”.Check” for additional information. Stop the engine and check the oil level in the steering tank. “Prepare the Machine for Maintenance”. Remove the filler strainer. Drain the oil into a suitable container. The oil level in the lower sight gauge should be within green range (B). 4. 7. Allow the cap and the strainer to dry. Remove tank drain valve plug (3). Discharge from the secondary steering accumulators could overfill the tank when the engine is stopped. Refer to Operation And Maintenance Manual. 6. Remove filler cap (1) in order to prevent a vacuum in the tank. check the secondary steering. refer to Operation and Maintenance Manual. If the oil level in the lower sight gauge is low. nonflammable solvent. Refer to Operation And Maintenance Manual. “Capacities (Refill)”. Remove the pipe nipple. use the reading from lower sight gauge (3) to maintain the steering oil level. Clean the drain plug and install the drain plug. 5. Refer to Operation and Maintenance Manual. . NOTICE Do not fill the steering hydraulic tank when the engine is running. 10.50 inch) long NPT pipe nipple in order to open the internal drain valve. “Hydraulic Tank Oil Level Check (Steering System)”. 1. Prepare the machine for maintenance. Note: When the engine is running. “Secondary Steering . i03585145 Illustration 235 g01913453 Hydraulic Tank Oil Level Check (Steering System) SMCS Code: 5056-535-FLV Note: The steering system and the hydraulic fan drive motor for the engine share common hydraulic oil. 9. Install a 88.

Consult your Caterpillar dealer for more information. i03657085 Indicators and Gauges .Test SMCS Code: 7000-081. 2.Change (If Equipped with Electric Lubrication Pump) Illustration 236 g01913481 SMCS Code: 7516-044-OC Note: Machines that are equipped with an air (engine) start arrangement have an air drive lubrication pump. “Monitoring System”. refer to Operation and Maintenance Manual. “Prepare the Machine for Maintenance”. 2. Turn the engine start switch to the OFF position. Check for broken lenses on the gauges. For more information. Note: If the oil level must be checked with the truck body in the RAISED position. The functional test will test the gauges. 3. 7450-081. 7490-081 1. If necessary. 4. The oil level must be within green range (A) on the sight gauge. When the hoist/brake tank is filled. stair assembly. see this Operation and Maintenance Manual. alarms. it may be necessary to use a portable access system (ladder. the oil will flow into the hoist reservoir. and the filler cap. Note: The hoist reservoir and the brake reservoir are separated by a baffle. Prepare the machine for maintenance. 1. After the brake reservoir is at the proper level. Check the oil level in the hoist/brake system with the dump body in the DOWN position. and other broken components in the operator station. 3. . or other portable access system) that is suitable and compliant to local regulations.Check i03585225 Hydraulic Tank Oil Level Check (Hoist and Brake System) SMCS Code: 5056-535-FLV Note: In order to access the sight gauges. remove filler cap (1) and add oil. Use sight gauge (2) in order to check the oil level in the brake reservoir. Refer to Operation and Maintenance Manual. 5. Turn the engine start switch from the OFF position to the ON position. This will initiate a functional test of the monitoring system. man lift. i04381144 Lubrication Pump Oil . the minimum oil level must be within sight gauge (4) with the engine on. Only machines that are equipped with an electric start arrangement have an electric drive lubrication pump. Sound the horn. If the system has been drained. Make any necessary repairs before machine operation.SEBU8406-04 207 Maintenance Section Hydraulic Tank Oil Level . 4. indicators. Listen for proper operation. the brake reservoir will fill first. Use sight gauge (3) in order to check the oil level in the hoist reservoir. broken switches. “Hydraulic Tank Oil Change (Hoist and Brake Oil)” for the proper filling procedure. and display. Observe the functional test in order to determine the proper operation of the monitoring system. The oil level must be within green range (B) on the sight gauge. broken indicator lights.

“Prepare the Machine for Maintenance”. Maintain the oil level at indicator (2) on the gauge. Inspect the gauge in order to determine the oil level. 3. Illustration 239 Magnetic plug on the rear wheel g01913494 . “Lubricant Viscosities”. add oil. 5. Maintain the oil level at indicator (3) on the gauge. Refer to Operation and Maintenance Manual. “Capacities (Refill)”. Prepare the machine for maintenance. If necessary.Check SEBU8406-04 1. Only machines that are equipped with an electric start arrangement have an electric drive lubrication pump. Lubrication Pump Oil Level Check (If Equipped with Electric Lubrication Pump) SMCS Code: 7516-535-FLV Note: Machines that are equipped with an air (engine) start arrangement have an air drive lubrication pump. 4. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. Remove oil level gauge (dipstick) (1). 1. Fill the electric lubrication pump with oil through the filler port. Refer to Operation and Maintenance Manual. Remove oil level gauge (dipstick) (1). i04380972 Magnetic Plug (Wheels) Check SMCS Code: 0663 1. 3. 2.208 Maintenance Section Lubrication Pump Oil Level . Illustration 238 g02546737 Illustration 237 g02547383 2. Refer to Operation and Maintenance Manual. i03585261 2. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. Stop the machine on a level surface and rotate one of the wheels so that the magnetic plug is above the center line of the wheel. Prepare the machine for maintenance. Use a suction device in order to extract the oil through filler port (2). Prepare the machine for maintenance.

rod bearings.Inspect i02106227 Oil Filter . If metals are found in the filter element. 4. An excessive amount of debris in the filter element can indicate a possible failure. Check the magnetic plug. Small amounts of debris may be found in the filter element. After you correct a failure that produces debris. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. Ferrous metals can indicate wear on steel parts and on cast iron parts. Use a filter cutter to cut the filter element open. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Spread apart the pleats and inspect the element for metal and for other debris. and to other parts. Repeat step 1 through step 3 for each wheel. If any abnormal particles are found. clean the compartments before you add any oil. A bearing failure is indicated by an increased amount of metal on the magnetic plug. consult your Caterpillar dealer. This can result in larger particles in unfiltered oil. or turbocharger bearings. Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. The magnetic plugs will attract metal from the oil. g00100013 3. a magnet can be used to differentiate between ferrous metals and nonferrous metals. All of the wheels have a magnetic plug. This could be caused by friction and by normal wear.SEBU8406-04 209 Maintenance Section Oil Filter .Inspect SMCS Code: 5068-040 Inspect a Used Filter for Debris Illustration 240 Magnetic plug on the front wheel g01913493 Illustration 241 The element is shown with debris. . The particles could enter the lubricating system and the particles could cause damage. to the crankshaft.

Refer to Operation and Maintenance Manual.210 Maintenance Section Platform (Powered Stairway) . Radiator. 1805. Aftercooler and Air Conditioner Condenser . Remove the access panels on each side of the cowl . 1. the aftercooler. Use a water spray nozzle that will disperse the water.Clean SMCS Code: 1064-070. Illustration 242 g02078415 2. Prepare the machine for maintenance. . and the air conditioner condenser. Lubricate fittings (3) for the shaft bearings. Illustration 243 g02079553 4. 1353-070-KO. “Prepare the Machine for Maintenance”. Remove tread plate (1) from the platform of the powered stairway. Illustration 244 g01923058 2. Refer to Operation and Maintenance Manual. 7320-070 NOTICE High water pressure water and high water volume can damage the fins on the radiator. 1805-070. 5.Lubricate SEBU8406-04 i03829762 i03597961 Platform (Powered Stairway) Lubricate (If Equipped) SMCS Code: 7254-086 1. Wipe off the fittings before any lubricant is applied. “Prepare the Machine for Maintenance”. Prepare the machine for maintenance. Lubricate fittings (2) for the hydraulic cylinder. 3.

Clean SMCS Code: 3282-070-MGS Hot oil and hot components can cause personal injury. Install the access panels. Illustration 246 Location of the magnetic screen for the rear axle g01950353 The right rear tires and wheels have been removed for ease of viewing. . and the air conditioner condenser. Clean the radiator. high pressure water. Note: Excessive amounts of accumulated debris may require the removal of the stair assembly and the grill panels in order to effectively clean the radiator. Use compressed air. and the air conditioner condenser. Refer to Special Publication. the aftercooler. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.SEBU8406-04 211 Maintenance Section Rear Axle Lubrication Magnetic Screen . maintenance. i03634685 Rear Axle Lubrication Magnetic Screen . Refer to Operation and Maintenance Manual. 4. NENG2500. Illustration 245 g01923089 3. and the air conditioner condenser. Dispose of all fluids according to local regulations and mandates. the aftercooler. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. “Prepare the Machine for Maintenance”. 1. Prepare the machine for maintenance. the aftercooler. Do not allow hot oil or hot components to contact the skin. or steam to remove dust and other debris from the radiator. adjusting and repair of the product.Clean NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.

10. Dispose of all fluids according to local regulations and mandates. Do not allow hot oil or hot components to contact the skin. the screen. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Replace SEBU8406-04 Note: The differential and final drive oil level needs to be checked and maintained at operating temperature.Replace SMCS Code: 5068-510 Illustration 247 g01916493 2. Note: The lubrication pump for the rear axle will not operate with the oil temperature below −4° C (25° F) and the lubrication pump for the rear axle will not operate if the machine is not moving for five minutes. Hot oil and hot components can cause personal injury. 4. Note: Correct oil levels are critical in the differential and final drives. If the element continues to become plugged after 50 service hours. Install the magnetic tube assembly. add oil. Check for leaks and make any necessary repairs.Check”. Remove wave washer (2). Note: The machine is shipped with a 6 micron filter element for the rear axle. 7. If the seal is damaged. . Wash the screen and the magnetic tube assembly in clean. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. If necessary. refer to Operation and Maintenance Manual. 5. replace the seal. “Differential and Final Drive Oil . Caterpillar recommends the use of a 6 micron element for the initial 50 service hours. consult your Caterpillar dealer. Check the oil level after repairs and after maintenance. replace the 6 micron element with another 6 micron element. nonflammable solvent. screen (3). Remove screen cover plate (1) for the magnetic screens. Check the oil level in the rear axle. Park the machine according to the guidelines in Operation and Maintenance Manual.212 Maintenance Section Rear Axle Oil Filter . Refer to Special Publication. For the proper procedure. “Prepare the Machine for Maintenance”. Operate the machine on level ground for a few minutes. Install the screen cover plate. i03598480 Rear Axle Oil Filter . NENG2500. and magnetic tube assembly (4). 6. a stiff bristle brush or air pressure. 3. adjustment of the oil level may be necessary when the truck reaches operating temperature. 8. maintenance. testing. and the wave washer. Replace any damaged magnets. If the 6 micron element becomes plugged before the initial 50 service hours. Inspect seal (5). adjusting and repair of the product. If the oil level is checked cold. NOTICE Do not drop or rap the magnets against any hard objects. 9. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Clean the magnets with a cloth.

Remove the end cap from the filter housing. Inspect the seal for the end cap. Check the oil level in the rear axle. refer to Operation and Maintenance Manual. Remove the filter element. Wash the drain plug in clean nonflammable solvent and install the drain plug. 7. Replace a damaged seal with a new seal. 2.Replace 8. Remove the drain plug from end cap (1). 3. 5. For the proper procedure. Note: The lubrication pump for the rear axle will not operate with the oil temperature below −4° C (25° F) and the lubrication pump for the rear axle will not operate if the machine is not moving for five minutes. 10.SEBU8406-04 213 Maintenance Section Rear Axle Oil Filter .Check”. If the oil level is checked cold. 6. “Differential and Final Drive Oil . Note: Correct oil levels are critical in the differential and final drives. “Prepare the Machine for Maintenance”. Check the oil level after repairs and after maintenance. Install the new filter element. 1. add oil. Check for leaks and make any necessary repairs. Drain the oil into a suitable container. Replace a damaged seal with a new seal. Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. adjustment of the oil level may be necessary when the truck reaches operating temperature. Illustration 248 g01923274 The left rear tires and wheels have been removed for ease of viewing. 9. Wash the end cap in clean nonflammable solvent. Inspect the seal for the drain plug. Park the machine according to the guidelines in Operation and Maintenance Manual. 4. If necessary. Install the end cap on the filter housing. . Operate the machine on level ground for a few minutes. Properly discard the used filter element. Prepare the machine for maintenance.

Slowly loosen the fitting. “Prepare the Machine for Maintenance”. Prepare the machine for maintenance. If the system is still under pressure. the receiver-dryer must be replaced.Replace SEBU8406-04 i03662161 Receiver Dryer (Refrigerant) Replace SMCS Code: 7322-510 Personal injury can result from contact with refrigerant. Refer to Operation and Maintenance Manual. Cutaway view of the air conditioner group 1. 2. Prepare the machine for maintenance. Refer to Service Manual. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes.214 Maintenance Section Receiver Dryer (Refrigerant) . Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas. Consult your tire dealer for dismounting the tires from the rims. 2. can cause bodily harm or death. Refer to Operation and Maintenance Manual. SENR5664. . Keep face and hands away to help prevent injury. Contact with refrigerant can cause frost bite. Illustration 249 g01964773 Protective goggles must always be worn when refrigerant lines are opened. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. release it slowly in a well ventilated area.Inspect SMCS Code: 4209-040 1. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. “Air Conditioning and Heating R-134a for All Caterpillar Machines” for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas. Always use precaution when a fitting is removed. even if the gauges indicate the system is empty of refrigerant. i03657420 Rim . “Prepare the Machine for Maintenance”. Refrigerant dryer receiver (1) is located inside the air conditioner group at the rear of the cab. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.

For more information on the reusability of the rim components. and cracks. Do not reuse rim components that are cracked. . consult your Caterpillar dealer. flat spots. cracks. For more information on the reusability of the rim components. Perform a magnetic particle inspection of the following high stress areas of the rim: • (1) Areas of contact with flanges • (2) Contact areas with the lock ring and the groove for the lock ring Illustration 251 Typical example Cutaway view of the rim assembly g01330970 • (3) Welds on the rim disc • (4) Welds around the circumference of the rim base Inspect the following components of the rim assembly: Bead Seat Band (1) – Inspect the bead seat band for the following: wear.Inspect SMCS Code: 4209-040 Inspect the rim whenever a tire is dismounted. cracks. corrosion. corrosion. and warping. damaged. “General Salvage and Reconditioning Techniques” or consult your Caterpillar dealer. Lock Ring (2) – Inspect the lock ring for the following: wear. corrosion. SEBF8148. consult your Caterpillar dealer. Flanges (4) – Inspect the flanges for the following: wear. • (5) Butt welds For more information on magnetic particle inspection. When the lock ring is not assembled.Inspect i02650497 Rim . the two ends of the lock ring must overlap each other. and fretting. and fretting.SEBU8406-04 215 Maintenance Section Rim . damaged. Do not reuse rim components that are cracked. worn. or pitted from corrosion. worn. Rim Base (3) – Inspect the rim base for the following: wear. cracks. Illustration 250 Typical example Cutaway view of the rim assembly g01331173 3. refer to Guideline For Reusable Parts And Salvage Operations. or pitted from corrosion. corrosion.

i03608760 Seat Belt . “Torque Specifications”.216 Maintenance Section Rollover Protective Structure (ROPS) . Illustration 253 Typical examples (1) Seat belt mounting hardware (2) Seat belt buckle (3) Webbing g01933953 Check all of the seat belt mounting hardware for wear or for damage. There is a pin on each corner of the cab. Improper bolt torque can result if you do not apply oil to the threads. 5. Do not weld reinforcement plates to the ROPS in order to repair the ROPS. “Inspection. Tighten any loose bolts for the ROPS mounting supports. Inspect ROPS (2) for any cracks in the welds. Replace any mounting hardware that is worn or damaged. Note: Do not reuse a bolt after the bolt has been removed.Inspect SMCS Code: 7327-040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. 2. or cracks in any metal section. Note: Do not weld reinforcement plates to the ROPS in order to straighten the ROPS. SEHS6929. . Inspect ROPS mounting supports (4) for loose bolts. Refer to Special Instruction. SENR3130. Maintenance. Replace any damaged mounting bolts and any missing mounting bolts with original replacement parts only. and Repair of ROPS and Attachment Installation Guidelines” or consult your Caterpillar dealer for more information. cracks in the castings. “Prepare the Machine for Maintenance”. Make sure that all of the mounting bolts are tight.Inspect SMCS Code: 7325-040 4. Tighten loose bolts that retain the pins.Inspect SEBU8406-04 i03118490 Rollover Protective Structure (ROPS) . Prepare the machine for maintenance. For bolts with a torque specification that is not stated. Note: Do not weld on the ROPS mounting supports. Refer to Operation and Maintenance Manual. Tighten the mounting bolts to a torque of 800 ± 100 N·m (590 ± 74 lb ft). 3. Inspect the ROPS for pins (1) that are loose or damaged. Note: Apply oil to all bolt threads for the ROPS before you install the bolts. Replace any damaged pins and any missing pins with original replacement parts only. refer to Specifications. Inspect the Rollover Protective Structure (ROPS) for mounting bolts (3) that are loose or damaged. Illustration 252 g01962353 1. Replace any parts that are damaged or worn before you operate the machine.

Refer to Operation and Maintenance Manual. RENR8391. refer to Systems Operation. Inspect Seat Suspension 2. Move the seat rearward and forward several times in order to distribute the lubricant. also perform this replacement procedure for the seat belt extension. Lubricate Seat Suspension 3. If your machine is equipped with a seat belt extension. Pivot the armrest to the vertical position. 7324-086 1.Check SMCS Code: 4300-535-SST Illustration 254 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended Web) of manufacture (underside) (buckle) g01152685 Consult your Cat dealer for the replacement of the seat belt and the mounting hardware. Special equipment is required for testing and charging. Hydraulic accumulator contains gas and oil under high pressure. A date label for determining the age of the seat belt is attached to the seat belt. Replace the seat belt at the date which occurs first.Replace SMCS Code: 7327-510 Within 3 years of the date of installation or within 5 years of the date of manufacture.SEBU8406-04 217 Maintenance Section Seat Belt . Armrest (Seat) 4. Adjust the seat fully forward and apply a dry lubricant to the rear of the seat slide mechanism. replace the seat belt. . Testing and Adjusting. If excessive looseness or wear is detected. Adjust the seat fully rearward and apply a dry lubricant to the front of the seat slide mechanism.Replace Check the seat belt buckle for wear or for damage. also perform this inspection procedure for the seat belt extension. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. and the seat belt retractor. the seat belt buckle. i03601440 Secondary Steering . Replace the seat belt at the date which occurs first. Inspect the seat suspension for excessive looseness and wear. If your machine is equipped with a seat belt extension. Replace the seat belt if the webbing is worn or frayed. Seat Belt . instructions in the service manual must be followed. If the buckle is worn or damaged. i04270251 i03662115 Seat Suspension Inspect/Lubricate SMCS Code: 7324-040. A date label for determining the age of the seat belt is attached to the seat belt. “Troubleshooting Chart”. “Caterpillar Comfort Series Seat with three point operator restraint”. the seat belt buckle. Apply dry lubricant or silicone lubricant between the parts in the mechanism for the armrest assembly. To remove or repair. Disassembly and Assembly. Improper removal or repair procedures could cause severe injury. replace the seat belt. and the seat belt retractor. Caterpillar recommends replacing the seat belt. “Prepare the Machine for Maintenance”. Note: Within three years of the date of installation or within five years of the date of manufacture. Prepare the machine for maintenance. Inspect the seat belt for webbing that is worn or frayed.

The hydraulic steering accumulators provide a limited amount of stored hydraulic pressure for steering if the power source for the normal steering system fails or the engine stops. a. check the steering hydraulic oil level. When the engine is stopped with the engine start switch. the accumulators are properly charged. 1. Inspect the machine and correct the condition which made the use of the secondary steering necessary. 3. Illustration 255 (1) Steering accumulators g01926214 2. If the secondary steering activates during operation. “Prepare the Machine for Maintenance”. Refer to Operation and Maintenance Manual. Maintain the oil within green range (A) of upper sight gauge (2). Perform the test when the dump body is empty. This machine is equipped with a secondary steering system. The secondary steering system will only provide steering until the stored hydraulic pressure is exhausted from steering action by the operator. After engine start-up. . If the oil level within green range (B) of lower sight gauge (3) is proportional to the oil level within the green range of the upper sight gauge level in step 2. Do not continue to operate the machine using the secondary steering. Prepare the machine for maintenance. immediately park the machine in a safe location.218 Maintenance Section Secondary Steering . Illustration 256 g01926205 Perform the following field test in order to verify that the secondary steering system is functional.Check SEBU8406-04 Personal injury or death can occur if steering is lost completely during operation. check the oil level.

Inspect the rear brakes for wear and inspect the rear brakes for system leakage. SEBF8095. Chock the rear wheels and move the transmission control in the N position. Testing and Adjusting. Turn the front wheels to the straight ahead position. “793F Off-Highway Truck Steering System”. 4.Inspect b. . consult your Caterpillar dealer. refer to Systems Operation. Verify that the front wheels turn right as the steering wheel is turned right. Refer to System Operation.Check”. Brake Discs 1. “Service Brake Discs . “793F Air System and Brake System”. refer to Systems Operation. 2. Testing and Adjusting. i03808552 Service Brakes . “793F Air System and Brake System”. Testing and Adjusting. KENR8572. “Service Brakes and Retarder System Pressure Test” or contact your Caterpillar dealer. Stop the engine with ground level shutdown switch (4).Test and Charge” or consult your Caterpillar dealer. Compare subsequent measurements to the initial measurement in order to determine the amount of wear. Refer to Operation and Maintenance Manual. If the secondary steering system is unable to comply with any portion of this field test. Verify that the front wheels turn left as the steering wheel is turned left. KENR8574. Visually confirm the following: a. record the initial measurement when the machine is new or when the brakes are rebuilt. “Service Brakes for Off-Highway Trucks and Tractors” when you rebuild the brakes.Inspect SMCS Code: 4251-040 Prepare the machine for maintenance. check accumulator charge before proceeding to the next step. 7. 5. For information on the proper inspection procedures. If the machine is equipped with brake wear indicators. “Prepare the Machine for Maintenance”. Illustration 257 g01926207 6. 3. If the oil level is below the green range in the lower sight gauge. For more information on the proper procedures.SEBU8406-04 219 Maintenance Section Service Brakes . This permits the accumulators to stay charged in order to provide stored energy for the secondary steering system when the engine is stopped. b. “Accumulator (Steering) . Brake Pressure Test the system pressure for the service brakes and retarder. KENR8572. Note: Refer to Guideline for Reusable Parts and Salvage Operations. Inspect the front brakes for wear and inspect the brake system for leakage.

perform the necessary repairs and/or replace any damaged sound suppression covers or hardware. perform the necessary repairs and/or replace any damaged sound suppression covers or hardware. 7076-510. Panels) . 1801-510. 7076-040.Inspect/Replace SEBU8406-04 i04322554 • Broken pieces • Cracks • Loose covers • Missing pieces If any of these conditions exist.If Equipped) Sound Covers (S/N: SND) Illustration 258 (1) Sound covers for the muffler g02499156 Inspect the sound covers for the following damage: Illustration 260 (3) Sound cover for the torque converter (4) Sound cover for the transmission g02479898 • Broken or missing hardware • Insulation material with fluid saturation • Loose insulation material • Missing pieces of insulation material • Tears in the insulation material Inspect the sound covers for the following damage: • Broken or missing hardware • Broken pieces • Cracks • Loose covers • Missing pieces If any of these conditions exist. Illustration 259 (2) Sound covers for the engine g02498776 Inspect the sound covers for the following damage: • Broken or missing hardware .Inspect/Replace SMCS Code: 1801-040. 7261-040. Panels) . 7261-510 Sound Covers (S/N: SND) and (S/N: SSP .220 Maintenance Section Sound Suppression (Covers. Sound Suppression (Covers.

and lead to the loss of steering. The inspection procedure does not require the ball studs to be removed from the machine.Inspect Sound Panels (S/N: SND) Sound Louvers (S/N: SND) Illustration 262 (10) Sound louvers for the grill g02479979 Inspect the sound louvers for the following damage: • Broken or missing hardware Illustration 261 (5) (6) (7) (8) (9) Hood enclosure sound panels Dump body sound panels Rear frame sound panel Bottom enclosure sound panels Side enclosure sound panels g02479821 • Bent or broken steel mesh • Compressed insulation material • Broken pieces • Cracks • Loose louvers • Missing pieces If any of these conditions exist. perform the necessary repairs and/or replace any damaged louvers or hardware. perform the necessary repairs and/or replace any damaged sound suppression material. The inspection procedure is used to identify any damage that has developed during the operation of the machine. 1. Prepare the machine for maintenance. The inspection procedure references ASTM E114-95 and ASTM E1901-97.Inspect SMCS Code: 4305-040-SD The inspection procedure for the ball studs uses a straight beam examination. “Prepare the Machine for Maintenance”. Steering Ball Stud . or hardware. panels. The ball studs can develop cracks that may cause the ball stud to fail.SEBU8406-04 221 Maintenance Section Steering Ball Stud . . Refer to Operation and Maintenance Manual. i03657827 Inspect the sound suppression panels for the following damage: • Broken or missing hardware • Burnt insulation material • Compressed insulation material • Insulation material with fluid saturation • Loose insulation material • Missing pieces of insulation material • Tears in the insulation material • Bent or broken steel panels If any of these conditions exist.

To measure the horizontal wear of the ball studs and of the outer bearing races on the other ball studs and outer bearing races. Note: Properly lubricate the steering linkage in order to ensure the durability of components. Set the dial indicator to zero. “Prepare the Machine for Maintenance”. Prepare the machine for maintenance.Inspect SMCS Code: 4305-040 Inspect the horizontal wear limits for the ball studs in the steering linkage. 8. and 797 Off-Highway Trucks” or consult your Caterpillar dealer in order to determine whether the tapered bore can be reused or machined to an oversized dimension. and grade of the haul road. If the tapered bore is out of the specification and the tapered bore is able to be salvaged. place the dial indicator against the side of center arm (3). “Steering Ball Stud Inspection for Off. 9.Highway Trucks” in order to perform the proper inspection procedure for the ball studs. inspect the grease fittings and the seals. Inspect all grease fittings and seals. 10. The replacement interval may vary and the replacement interval is heavily dependent on the haul cycle conditions. either the steering arm or the steering box must be scrapped and replaced. length of hauls. Steering Linkage . If any of the measurements exceed this limit. SEBF8271. Replace any worn components and any damaged components. Steer the front wheels in both directions. place the dial indicator against the side of steering arm (1). Refer to Reuse and Salvage Guidelines. Refer to Special Instruction. Also. Attach the magnetic base of a 8T-5096 Dial Indicator Group to steering link (2). REHS4420. Record the amount of horizontal play on the indicator dial. i03657829 Illustration 263 Typical example (1) Steering arm (2) Steering link assembly (3) Center arm g01442892 2. “Salvage of Steering Arm and Steering Arm (T-Bar) Tapers on 785. 3.Replace SEBU8406-04 2.222 Maintenance Section Steering Ball Stud . Set the dial indicator to zero. For the replacement procedure. refer to the Disassembly and Assembly. The steering linkage must be free of contaminants in order to ensure the durability of components. Refer to Operation and Maintenance Manual. In this case. Refer to Operation and Maintenance Manual. At the same time. i03657828 Steering Ball Stud . . 1. Prepare the machine for maintenance. inspect the outer bearing race. then an oversize ball stud cannot be used. then an oversize ball stud may be used. These conditions include the following considerations: haul road condition.02 mm (0. 793. “Off-Highway Truck Machine Systems” manual for your machine or consult your Caterpillar dealer. 6. load. Note: Repeat this procedure in order to measure all of the ball studs and outer bearing races. This indicates the amount of wear in the ball studs and the outer bearing races. 1. This will allow the horizontal movement of the ball stud to be measured. replace the worn ball studs and the outer bearing races. If the taper is too far out of the specification. number of turns per cycle.Replace SMCS Code: 4305-510-SD The recommended replacement interval for the steering cylinder and steering linkage ball studs is between 12000 operating hours and 15000 operating hours or at the planned component rebuild of the steering cylinder. Inspect all of the covers for the ball studs.040 inch). The maximum amount of horizontal wear is 1. To measure the horizontal wear of the ball studs and of the outer bearing races on the steering cylinders. 2. 5. 7. 4. Record the amount of horizontal play on the indicator dial. “Prepare the Machine for Maintenance”. Inspect the condition of the tapered steering bore whenever a ball stud is replaced. Steer the front wheels in both directions. 789.

If those dimensions are not available. Do not plug the grease passage of the relief valves. Measure the distance of exposed finished surface (Y) for the front suspension cylinders. “Tire Inflation Information” for more tire information.SEBU8406-04 223 Maintenance Section Suspension Cylinder . SEHS9411. Prepare the machine for maintenance. Refer to Special Instruction. 1. Tire Inflation . check the charge pressure.Check SMCS Code: 4203-535-AI. Illustration 265 Rear Suspension Cylinder (Y) Distance of exposed finished surface g01964614 6. 5. Refer to Operation and Maintenance Manual. Compare the present distance to the distance from the previous time. During field assembly. pressures. perform the charging procedure on the rear suspension cylinders. 2. “Servicing the Suspension Cylinders for Off-Highway Trucks” for any information concerning suspension cylinders. Compare the present distance to the distance from the previous time. that are used on all off-highway truck suspension cylinders. Prepare the machine for maintenance. See Operation and Maintenance Manual. Note: There are two relief valves for the grease on the forward side of the front suspension cylinder. Consult your tire supplier for the correct tire operating pressures and load ratings. 3. perform the charging procedure on the front suspension cylinders. the left rear suspension cylinder will not show as much finished surface as the right rear suspension cylinder. the suspension cylinders must be charged with nitrogen. Refer to Operation and Maintenance Manual. “Prepare the Machine for Maintenance”. 7. i03657830 Illustration 264 Front Suspension Cylinder (X) Distance of exposed finished surface g01583894 4. This is due to the rigid frame and to the weight of the cab. These relief valves are located 180 degrees from the lubrication fitting. Measure the tire pressure on each tire. if necessary. “Prepare the Machine for Maintenance”. Measure the distance of exposed finished surface (X) for the front suspension cylinders. Note: When the rear suspension cylinders are properly charged. If those dimensions are not available. Stop the machine gradually on a level surface without using the brakes. Adjust the tire pressure. If necessary. 4203-535-PX 1. and the correct procedures for purging (oil and nitrogen) and charging (oil and nitrogen). If necessary. check the charge pressure. 2.Check SMCS Code: 7201-535 Note: All of the suspension cylinders that are shipped from the factory receive a preliminary charge of nitrogen and a preliminary charge of oil. The Special Instruction includes tooling.Check i03588400 Suspension Cylinder . . Check the suspension cylinders when the dump body is empty.

Remove the filter element. Note: The torque converter and the transmission share common oil.Check”. Wash the end cap in clean nonflammable solvent. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Inspect the seal for the drain plug. Do not allow hot oil or hot components to contact the skin. Make any necessary repairs. Wash the drain plug in clean nonflammable solvent and install the drain plug. Start the engine and operate the engine at an idle for five minutes. Prepare the machine for maintenance. Inspect the seal for the end cap. 5. “Prepare the Machine for Maintenance”. 1. 3. Install the new filter element. Illustration 266 g01914729 2. Replace a damaged seal with a new seal. Refer to Operation and Maintenance Manual. Refer to Special Publication. Install the end cap on the filter housing.224 Maintenance Section Torque Converter Oil Filter . testing. 4. 5068-510-VC Hot oil and hot components can cause personal injury. Replace a damaged seal with a new seal. refer to Operation and Maintenance Manual. 6. 7. If necessary. Drain the oil into a suitable container. 3101-510-FI. Properly discard the used filter element. NENG2500. . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 8. maintenance. Remove the end cap from the filter housing. Remove drain plug (2) from end cap (1). Dispose of all fluids according to local regulations and mandates. Inspect the oil filter for leaks. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. For the proper procedure.Replace SEBU8406-04 i03586741 Torque Converter Oil Filter Replace SMCS Code: 3004-510. adjusting and repair of the product. 9. Check the oil level in the torque converter sump. “Torque Converter Sump Oil Level . add oil.

SEBU8406-04 225 Maintenance Section Torque Converter Outlet Screen . 6. adjusting and repair of the product. 7. replace the seal with a new seal. 1. Do not allow hot oil or hot components to contact skin.Replace i03589523 Torque Converter Outlet Screen . Wash the screen housing in clean.Replace SMCS Code: 3103 Hot oil and hot components can cause personal injury. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Start the engine and operate the engine at an idle. Dispose of all fluids according to local regulations and mandates. Remove drain plug (1) from the bottom of screen housing (2) and drain the oil into a suitable container. nonflammable solvent. Refer to Special Publication. NENG2500. 4. Clean the drain plug and install the drain plug. . Prepare the machine for maintenance. Illustration 267 g01916393 2. Refer to Operation and Maintenance Manual. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 3. Inspect the seal in the base of the screen housing. maintenance. Remove the screen housing. If the seal is damaged. Note: Removing the drain plug from the bottom of the screen housing may not drain all of the oil from the screen. Install the screen housing. Install the new screen in the screen housing. Check for leaks and make any necessary repairs. Make sure that the parking brake is engaged. Discard the used screen. Remove the screen. “Prepare the Machine for Maintenance”. 5. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. testing.

. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. “Torque Converter Sump Oil Level .Check”. If necessary. maintenance. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. “Prepare the Machine for Maintenance”.Check SEBU8406-04 8. Check the oil level in the torque converter sump with the engine at an idle. 1. i03589181 a. Prepare the machine for maintenance. Prepare the machine for maintenance.Clean SMCS Code: 3101 Hot oil and hot components can cause personal injury. “Prepare the Machine for Maintenance”. 1. Do not allow hot oil or hot components to contact the skin. b. Refer to Operation and Maintenance Manual. Dispose of all fluids according to local regulations and mandates. When the oil for the transmission and torque converter system is at operating temperature (hot). Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 3. NENG2500. testing. The torque converter oil and transmission oil is added at filler cap (3). Refer to Operation and Maintenance Manual. refer to Operation and Maintenance Manual. add oil. Check the oil level in the torque converter sump. Clean the screens whenever there is a failure in the transmission and torque converter system. Illustration 268 g01916154 2. If necessary. add oil. When the oil for the transmission and torque converter system is at ambient temperature (cold). maintain the oil level within the green range (B) of lower sight gauge (2). Torque Converter Sump Screen . i03600260 Torque Converter Sump Oil Level . Refer to Special Publication. adjusting and repair of the product.226 Maintenance Section Torque Converter Sump Oil Level . For the proper procedure.Check SMCS Code: 3101-535-FLV Note: The oil level in the transmission is supplied by the torque converter sump. maintain the oil level within the green range (A) of upper sight gauge (1).

“Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Start the engine. Refer to Operation and Maintenance Manual. Install a 88. i03600647 Torque Converter and Transmission Oil . Hot oil and hot components can cause personal injury. Drain the oil into a suitable container. 7. Inspect the cover seal. Refer to Operation And Maintenance Manual. Install the cover. replace the seal with a new seal. Clean the drain plug and install the drain plug. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Change 6. Fill the torque converter sump to the top of the green range of lower sight gauge (3) and install the filler cap. Illustration 270 g01924834 5. 3. 11. 10. nonflammable solvent. 9.0 mm (3. Remove the pipe nipple. Inspect the torque converter for leaks. 4. . Remove the cover and the screen. Do not allow hot oil or hot components to contact the skin. “Prepare the Machine for Maintenance”. NENG2500. 3101-044-OC 2. “Lubricant Viscosities” for the proper oil. Make any necessary repairs. maintenance. If the seal is damaged. Wash the screen in clean. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual. Refer to Special Publication. Check the oil level in the torque converter sump with the engine at an idle. testing.50 inch) long NPT pipe nipple in order to open the internal drain valve. 8.SEBU8406-04 227 Maintenance Section Torque Converter and Transmission Oil . “Torque Converter Sump Oil Level . NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 1.Check”. Remove filler cap (1) in order to prevent a vacuum in the sump. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). Install the screen. Dispose of all fluids according to local regulations and mandates. The oil level may decrease as oil circulates in the system.Change Illustration 269 g01924793 SMCS Code: 3030-044-OC. Allow the screen to dry. Clean any debris from the outside of cover (4). adjusting and repair of the product. Remove drain valve plug (2).

228 Maintenance Section Torque Converter and Transmission Oil Sample - Obtain

SEBU8406-04

6. Remove the filler strainer. Wash the cap and the strainer in clean, nonflammable solvent. Allow the cap and the strainer to dry. Install the strainer. 7. Inspect the cap seal. Use a new seal if the used seal is damaged. 8. Fill the torque converter sump to the top of the green range of the upper sight gauge . Refer to Operation And Maintenance Manual, “Lubricant Viscosities”. Refer to Operation And Maintenance Manual, “Capacities (Refill)”. 9. Start the engine. The oil level will decrease as oil fills the system. 10. Add oil to the torque converter sump with the engine at an idle in order to bring the transmission and torque converter oil to the proper level. Refer to Operation and Maintenance Manual, “Torque Converter Sump Oil Level - Check”. 11. Inspect the transmission and torque converter system for leaks. Make any necessary repairs.
i03600829

Torque Converter and Transmission Oil Sample Obtain
SMCS Code: 3030-008; 3101-008; 7542

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Illustration 271
g01925129

2. Remove filler cap (1) in order to prevent a vacuum in the sump. 3. Remove drain valve plug (2). Install a 88.0 mm (3.50 inch) long NPT pipe nipple in order to open the internal drain valve. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). Drain the oil into a suitable container. 4. Remove drain valve plug (3) and drain valve plug (4). Install a 88.0 mm (3.50 inch) long NPT pipe nipple in order to open the internal drain on both valves. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). Drain the oil into a suitable container. 5. Remove the pipe nipples. Clean the drain plugs and install the drain plugs.

Obtain S·O·S samples as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. 1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

SEBU8406-04

229 Maintenance Section Traction Control System (TCS) - Test

i03720443

Traction Control System (TCS) - Test
SMCS Code: 3288-081; 4801-081 Note: This procedure determines if the Traction Control System (TCS) is functioning. This procedure also determines if the left rear brake and the right rear brake activate at the correct time. 1. Find a clear area and a level area that is large enough to turn the machine in a complete circle. Start the machine and move the transmission control to the 1 position. 2. Turn the steering wheel all the way to the left. With the engine at an idle, slowly drive forward in a complete circle.

Illustration 272

g01925213

2. Obtain a sample of the transmission and torque converter oil through sampling valve (1). Take the oil sample when the engine is operating at an idle. 3. Submit the sample for S·O·S analysis. Refer to the following publications for S·O·S information:
Illustration 273
g02004873

The TCS test switch is located in the overhead controls in the operator station.

• Operation and Maintenance Manual, “S·O·S
Information”

• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “S·O·S Services Analysis” Good S·O·S Sample”

3. Continue to turn the machine and push the top half of TCS test switch (1). Hold the test switch down. This will begin the test. 4. The machine will gradually slow down. 5. Release the test switch. The test will end and the machine will increase speed. 6. Turn the steering wheel all the way to the right. With the engine at an idle, slowly drive forward in a complete circle. 7. Continue to turn the machine and push the top half of the TCS test switch. Hold the test switch down. This will begin the test. 8. The machine will gradually slow down. 9. Release the test switch. The test will end and the machine will increase speed.

• Special Publication, PEGJ0047, “How to Take a • Special Publication, PEGJ0046, “S·O·S Services:
Understanding Your Results” Analysis”

• Special Publication, PEHJ0191, “S·O·S Fluid

230 Maintenance Section Transmission Magnetic Screen - Clean

SEBU8406-04

10. If the TCS did not function properly, consult your Caterpillar dealer for information and service.
i03590300

Transmission Magnetic Screen - Clean
SMCS Code: 3030-070-MGS

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Illustration 275

g01916493

2. Remove screen cover plate (1) for one of the magnetic screens. 3. Remove wave washer (2), screen (3), and magnetic tube assembly (4). NOTICE Do not drop or rap the magnets against any hard objects. Replace any damaged magnets. 4. Wash the screen and the magnetic tube assembly in clean, nonflammable solvent. Clean the magnets with a cloth, a stiff bristle brush or air pressure. 5. Install the magnetic tube assembly, the screen, and the wave washer. 6. Inspect seal (5). If the seal is damaged, replace the seal. 7. Install the screen cover plate. 8. Repeat step 2 through step7 for the other magnetic screen. 9. Start the engine and operate the engine at an idle for five minutes. Check for leaks and make any necessary repairs. Note: The oil level in the transmission is supplied by the torque converter sump.
Illustration 274
g01916495

Location of the two magnetic screens for the transmission

1. Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, “Prepare the Machine for Maintenance”.

10. Check the oil level in the torque converter sump. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, “Torque Converter Sump Oil Level - Check”.

Inspect the oil filter for leaks. add oil. Window Washer Bottle . Inspect the seal for the drain plug. If necessary.Replace i03587440 Transmission Oil Filter Replace SMCS Code: 3067-510 1. Refer to Operation and Maintenance Manual. Refer to Special Publication. Replace a damaged seal with a new seal. “Prepare the Machine for Maintenance”. NENG2500. 4. refer to Operation and Maintenance Manual. Wash the end cap in clean nonflammable solvent. For the proper procedure. Do not allow hot oil or hot components to contact the skin. maintenance. The oil level in the transmission is supplied by the torque converter sump. Start the engine and operate the engine at an idle for five minutes. Install the new filter element. Remove the end cap from the filter housing. Replace a damaged seal with a new seal. Prepare the machine for maintenance. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. System damage can result from freezing. Drain the oil into a suitable container. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Check”. 5. 8. 2. Remove drain plug (2) from end cap (1). testing. 3. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Make any necessary repairs. Properly discard the used filter element. Remove the filter element. Illustration 276 g01914789 . Install the end cap on the filter housing. 9. “Torque Converter Sump Oil Level . 7. Wash the drain plug in clean nonflammable solvent and install the drain plug. Inspect the seal for the end cap. use Caterpillar nonfreezing window washer solvent or equivalent. 6.Fill SMCS Code: 7306-544-KE NOTICE When operating in freezing temperatures. Check the oil level in the torque converter sump.SEBU8406-04 231 Maintenance Section Transmission Oil Filter . i03661560 Hot oil and hot components can cause personal injury. adjusting and repair of the product.

i03661541 Illustration 279 Cab windows g01589433 Window Wiper Inspect/Replace SMCS Code: 7305-040. Prepare the machine for maintenance. 2. Remove filler cap (1) in order to fill the bottle with window washer solvent.Clean SMCS Code: 7310. Illustration 278 g01588854 . Refer to Operation and Maintenance Manual. Clean the windows with a commercially available window cleaning solution. 2.Inspect/Replace SEBU8406-04 1. Prepare the machine for maintenance. Only clean the windows when handholds are available. Prepare the machine for maintenance. 7305-510 1. Replace the window wiper blades if the wiper blades are worn or damaged. Refer to Operation and Maintenance Manual. 1. 2. Replace any window wiper blade that streaks the window. Inspect the window wiper blades. 7340 Illustration 277 g01964354 The filler spout for the washer fluid bottle is located on the left rear of the cab. “Prepare the Machine for Maintenance”. 3. Refer to Operation and Maintenance Manual. “Prepare the Machine for Maintenance”.232 Maintenance Section Window Wiper . i04218829 Windows . “Prepare the Machine for Maintenance”.